Processes for recovering products from a corn fermentation mash

ABSTRACT

Processes and systems for recovering products from a fermentation mash. In some examples, a process for recovering products from a fermentation mash can include processing a ground corn product to produce a fermentation mash that can include ethanol. At least a portion of the ethanol can be separated from the fermentation mash to produce a whole stillage. The whole stillage can be separated to produce a fiber rich product and a filtrate. The fiber rich product can be hydrolyzed to produce a saccharification mash. The saccharification mash can be processed to produce additional ethanol and a stillage protein product.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/529,025, filed on May 23, 2017, which is a National StageApplication under 35 U.S.C. § 371 of PCT/US2016/063666, filed on Nov.23, 2016, which claims priority to U.S. Provisional Patent ApplicationNo. 62/324,159, filed on Apr. 18, 2016, and to U.S. Provisional PatentApplication No. 62/260,181, filed on Nov. 25, 2015. This application isalso a continuation-in-part of U.S. patent application Ser. No.15/529,014, filed on May 23, 2017, which is a National Stage Applicationunder 35 U.S.C. § 371 of PCT/US16/63657, filed on Nov. 23, 2016, whichclaims priority to U.S. Provisional Patent Application No. 62/260,181,filed on Nov. 25, 2015. All of which are incorporated by referenceherein.

BACKGROUND Field

Embodiments described generally relate to processes and systems forrecovering products derived from ground corn. More particularly, suchembodiments relate to processes and systems for recovering products froma corn fermentation mash.

Description of the Related Art

Corn or maize is often used as a starch source to produce ethanol byfermentation. Corn is traditionally ground by a hammer mill in ethanolproduction facilities. Hammer milled corn has a very wide range of sizesand generally includes relatively large particle sizes.

The fermentation process produces a corn fermentation mash that includesa mixture of ethanol and multiple corn products. Ethanol is removed fromthe corn fermentation mash by distillation to produce a whole stillagethat contains a mixture of corn products. Many of these corn productsare too time consuming and/or costly to separate from the stillage andtherefore are never recovered as separate products.

There is a need, therefore, for improved processes and systems forrecovering products from a corn fermentation mash.

SUMMARY

Processes and systems for recovering products from a fermentation mashare provided. In some examples, a process for recovering products from afermentation mash can include processing a ground corn product toproduce a fermentation mash that can include ethanol. At least a portionof the ethanol can be separated from the fermentation mash to produce awhole stillage. The whole stillage can be separated to produce a fiberrich product and a filtrate. The fiber rich product can be hydrolyzed toproduce a saccharification mash. The saccharification mash can beprocessed to produce additional ethanol and a stillage protein product.

In other examples, a process for recovering products from a fermentationmash can include processing a ground corn product to produce afermentation mash that can include ethanol. At least a portion of theethanol can be separated from the fermentation mash to produce a wholestillage. The whole stillage can be separated with a fiber filter toproduce a fiber rich product and a filtrate. The fiber rich product canbe hydrolyzed to produce a saccharification mash. The saccharificationmash can be processed to produce additional ethanol and a stillageprotein product.

In some examples, a process for recovering products from a fermentationmash can include processing a ground corn product to produce afermentation mash that can include ethanol. At least a portion of theethanol can be separated from the fermentation mash to produce a wholestillage. The whole stillage can be separated to produce a fiber richproduct and a filtrate. The fiber rich product can have an ethanolpotential of at least 90 gallons of ethanol per 1,000 kilograms of thefiber rich product.

BRIEF DESCRIPTION OF THE DRAWINGS

So that the manner in which the above recited features can be understoodin detail, a more particular description, briefly summarized above, maybe had by reference to embodiments, some of which are illustrated in theappended drawing. It is to be noted, however, that the appended drawingillustrate only typical embodiments and are therefore not to beconsidered limiting of its scope, for the invention may admit to otherequally effective embodiments.

FIG. 1 depicts a schematic view of an illustrative system for recoveringproducts derived from corn fermentation mash, according to one or moreembodiments described.

FIG. 2 depicts a schematic view of an illustrative system for producingethanol from a fiber product recovered from a whole stillage, accordingto one or more embodiments described.

FIG. 3 depicts a schematic view of another illustrative system forproducing ethanol from a fiber product recovered from a whole stillage,according to one or more embodiments described.

FIG. 4 is an optical microscope image of hammer milled corn (ComparativeExample 1) at a magnification of 10×.

FIG. 5 is an optical microscope image of hammer milled corn (ComparativeExample 1) at a magnification of 200×.

FIG. 6 is an optical microscope image of roller milled corn (ComparativeExample 2) at a magnification of 10×.

FIG. 7 is an optical microscope image of roller milled corn (ComparativeExample 2) at a magnification of 200×.

FIG. 8 is an optical microscope image of disk pulverized corn(Example 1) at a magnification of 10×.

FIG. 9 is an optical microscope image of disk pulverized corn(Example 1) at a magnification of 200×.

FIG. 10 is an optical microscope image of disk pulverized corn (Example2) at a magnification of 10×.

FIG. 11 is an optical microscope image of disk pulverized corn (Example2) at a magnification of 100×.

FIG. 12 is an optical microscope image of disk fiberized corn (Example3) at a magnification of 10×.

FIG. 13 is an optical microscope image of disk fiberized corn (Example3) at a magnification of 200×.

FIG. 14 is an optical microscope image of disk fiberized corn (Example4) at a magnification of 10×.

FIG. 15 is an optical microscope image of disk fiberized corn (Example4) at a magnification of 200×.

DETAILED DESCRIPTION

FIG. 1 depicts a schematic view of an illustrative separation system 100for recovering products derived from fermented corn. Illustrativeproducts derived from fermented corn can include, but are not limitedto, ethanol, distillers grains, protein rich products, oil, and otherproducts. A ground corn product that can be produced from the corn, canbe processed to produce the fermented corn. The ground corn product canbe milled from a plurality of corn pieces by one or more high shearmills. For example, the plurality of corn pieces via line 101 can beintroduced into one or more high shear mills 102. The corn pieces, priorto being high shear milled, can be or include, but are not limited to,whole corn kernels, fragmented corn kernels, size-reduced corn kernels,milled corn kernels, ground corn kernels, fresh corn kernels, dried cornkernels, or any mixture thereof. In some examples, whole corn kernelscan be size-reduced via one or more non-high shear mills, such as one ormore hammer mills and/or one or more roller mills using a non-shearingtechnique, to produce a coarse ground corn. The coarse ground corn canbe further size-reduced, such as sheared, milled, or otherwise ground,in the high shear mill 102 to produce the ground corn product. The highshear mill 102 can be or include, but is not limited to, one or moredisk mill fiberizers, one or more air swept pulverizers, one or moreother high shear mills, or any combination thereof.

The ground corn product can have a particle size of less than a particlesize of conventional ground corn (e.g., hammer milled corn or rollermilled corn). For example, the ground corn product can have a d₅₀ byvolume percent of about 100 μm to about 500 μm, as measured according toISO 13320:2009. In contrast, hammer milled corn generally has a d₅₀ byvolume percent of greater than 500 μm and roller milled corn generallyhas a d₅₀ by volume percent of greater than 600 μm.

In some examples, greater than 25 wt % of the ground corn product canhave a particle size of greater than 105 μm and greater than 80 wt % ofthe ground corn product can have a particle size of 425 μm or less, asmeasured according to AOAC 965.22-1966. The particle size distributionof the ground corn product produced in the high shear mill is furtherdiscussed and described below. It has been surprisingly and unexpectedlydiscovered that when 80 wt % or more of the ground corn product has aparticle size of 425 μm or less and when greater than 25 wt % of theground corn product has a particle size of greater than 105 μm, one ormore product yields (e.g., corn oil) and/or one or more systemefficiencies is realized as compared to conventional ethanol productionprocesses that use a ground corn in which less than 80 wt % of theground corn has a particle size of 425 μm or less or when less than 25wt % (e.g., less than 20 wt %) of the ground corn product has a particlesize of greater than 105 μm.

The ground corn product produced in the high shear mill 102 can beprocessed or otherwise treated in one or more process units to produce afermentation mash. The process units can include one or multiple vesselsand/or apparatuses, such as slurry tanks and/or liquefaction tanks, forheating, mixing, separating, and/or carrying out other operations on theslurry. In some examples, the ground corn product via line 103 can betransferred from the high shear mill 102 to one or more slurry tanks104. Other components or products from downstream in the separationsystem 100 can also be mixed, blended, or otherwise combined with theground corn product in the slurry tank 104. The ground corn product canbe mixed, blended, or otherwise combined with water and one or moreenzymes, such as alpha-amylase, to produce a slurry tank mixture. One ormore optional additives and/or one or more optional recycled downstreamcomponents can also be mixed, blended, or otherwise combined with theground corn product, water, and enzyme to produce the slurry tankmixture. The slurry tank mixture can be processed to produce thefermentation mash. The slurry tank mixture can be heated to produce agelatinized starch. The gelatinized starch can be hydrolyzed to producea liquefaction mash. The liquefaction mash can be subjected tosaccharification and fermentation to produce the fermentation mash.

The slurry tank mixture can be heated in a cooker (e.g., a pressurizedjet cooker) to solubilize the starch in the ground corn product toproduce a solubilized mixture of gelatinized starch. The slurry tankmixture can be mixed using a paddle mixer, a ribbon blender, a densephase slurry mixer, or any combination thereof. The slurry tank mixturecan be heated to a temperature that is at or above the onset of starchgelatinization where the alpha amylase can solubilize the starch. In oneexample, this temperature can be above the temperature where the onsetof gelatinization occurs, but below the temperature needed to completegelatinization. The starch is hydrolyzed by the enzyme intomaltodextrins and oligosaccharides. Given sufficiently small particlesize the hydrolysis can occur without complete gelatinization. Lowertemperature liquefaction offers the benefit of reduced energy use andreduced damage to starch due to undesirable side reactions, such as theMaillard reaction, as well as a reduced formation of “dough balls”,which are lumps of corn flour that can form in the slurry tank mixtureand can reduce or cease the production of ethanol.

The slurry tank mixture in the slurry tank 104 can be heated to atemperature of less than 90° C., less than 85° C., less than 80° C.,less than 75° C., less than 72° C., or less than 70° C. For example, theslurry tank mixture can be heated to a temperature of greater than 50°C., greater than 55° C., greater than 60° C., greater than 62° C.,greater than 64° C., or greater than 66° C. to less than 90° C., lessthan 85° C., less than 80° C., less than 75° C., less than 72° C., orless than 70° C.

The solubilized mixture of gelatinized starch via line 105 can betransferred from the slurry tank 104 to one or more liquefaction tanks106. One or more enzymes, such as alpha-amylase, can be added to thesolubilized mixture of gelatinized starch in a liquefaction process toproduce a liquefaction mash containing a hydrolyzed mixture. The enzymecan hydrolyze the gelatinized starch into maltodextrins andoligosaccharides.

The liquefaction mash via line 107 can be transferred from theliquefaction tank 106 to one or more fermenters 108. The liquefactionmash containing the hydrolyzed mixture can be further processed in oneor more saccharification and fermentation processes to produce thefermentation mash. The saccharification and fermentation can occursequentially or simultaneously. During saccharification, the liquefiedmash can be cooled and one or more enzymes, such as glucoamylase, can beadded to hydrolyze the maltodextrins and oligosaccharides into singleglucose sugar molecules. During fermentation, one or more strains ofyeast, such as Saccharomyces cerevisae, can be added to metabolize theglucose sugars into ethanol and carbon dioxide. After saccharificationand fermentation, in some examples, the fermentation mash can includeabout 15 vol % to about 25 vol % of ethanol (volume/volume basis), aswell as remaining grain components.

The fermentation mash via line 109 can be pumped or otherwisetransferred from the fermenter 108 to one or more distillers 110 wherethe fermentation mash can be heated to vaporize at least a portion ofthe ethanol. The distiller 110 can be or include, but is not limited to,one or more distillation columns, one or more distillation trains, oneor more condensers, or other device(s) configured to vaporize theethanol and to condense the vaporized ethanol. The ethanol can bedistilled or otherwise separated from the fermentation mash within thedistiller 110 to produce a whole stillage. The whole stillage caninclude, but is not limited to, water, fibers, starches, oils, andproteins.

The vaporized ethanol can be condensed in a condenser within thedistiller 110, and liquid alcohol (e.g., ethanol) can be recovered fromthe distiller 110 at about 95 vol % purity (190 proof). The 190 proofethanol via line 111 can be transferred into one or more dehydrators 112and dried. The dehydrator 112 can be or include one or more dehydrationcolumns, such as molecular sieve dehydration columns. The 190 proofethanol can pass through the dehydration columns in the dehydrator 112that can remove residual water from the ethanol, to yield a drierproduct of purified ethanol, such as about 99.75 vol % of ethanol (about199.5 proof) that can be transferred via line 113 to one or more ethanolstorage containers 114.

The whole stillage left in the distiller 110 can be further processed toseparate and/or recover a variety of products. Illustrative productsthat can be derived from the whole stillage can include, but are notlimited to, other alcohols, oil products (e.g., a corn oil product),distillers grains (e.g., a wet fiber rich product, a wet fiber richproduct with syrup, a dried fiber rich product, and/or a dried fiberrich product with syrup), protein products (e.g., a protein richproduct), and/or other products from the whole stillage (e.g., a syrupproduct).

The whole stillage left in the distiller 110 can be transferred via line115 to one or more separators 116. The whole stillage can be contactedor otherwise processed in the separator 116 to separate or otherwiseproduce a fiber rich portion or fiber rich product via line 117 and afiltrate via line 119. For example, the fiber rich product can befiltered or otherwise removed from stillage by the separator 116 toproduce the filtrate that passes through the separator 116. The fiberrich product can include fibrous material, such as fibers. The fiberrich product can be used alone or combined with other components toproduce various types of products, as will be further discussed anddescribed below.

The separator 116 can be or include, but is not limited to, one or morepressure screens, one or more centrifuges (e.g., a filtration centrifugesuch as those discussed and described in U.S. Pat. Nos. 8,813,973 and8,778,433), one or more paddle screens, one or more fiber filters, oneor more rotary drum screens, one or more rotary vacuum drum filters, oneor more brush strainers, one or more vibratory separators, one or morecentrifugal screeners, one or more linear motion screens, one or morevacu-deck screens, or any combination thereof.

In some examples, the separator 116 can be or include a single pressurescreen. In other examples, the separator 116 can be or include two ormore pressure screens. In other examples, the separator 116 can be asingle pressure screen or two or more pressure screens and can be freeof or otherwise exclude any centrifuge. In another example, theseparator 116 be a single pressure screen or two or more pressurescreens and can be free of or otherwise exclude any centrifuge, paddlescreen, fiber filter, or any combination of centrifuge, paddle screen,and filter. In another example, the separator 116 can be a singlepressure screen or two or more pressure screens and can be free of orotherwise exclude any centrifuge, paddle screen, fiber filter, rotarydrum screen, rotary vacuum drum filter, brush strainer, vibratoryseparator, centrifugal screener, linear motion screen, and vacuum deckscreen. As such, in at least one example, the whole stillage in line 115can be separated into the fiber rich product via line 117 and thefiltrate via line 119 with only one or two or more pressure screens.

Illustrative pressure screens can be or include outflow pressurescreens, inflow pressure screens, inflow/outflow pressure screens,and/or foils on accept side of plate pressure screens. In an outflowpressure screen, the whole stillage can flow from the inside of thescreen plate cylinder to the outside, with the rotor being on the insideof the screen plate. The fibers can be held inside the plate until thefibers reach the reject port. In an inflow pressure screen, the wholestillage can flow from the outside of the screen cylinder to the insidewith the rotor being on the outside of the screen plate. The fibers canbe held on the outside of the cylinder. Suitable rotors can includefoiled rotors, bump rotors, lobe rotors, and/or S-rotors. The openingsin the pressure screens can be circular, slotted, or a combinationthereof. The pressure screen can be made by milling slots into a singlepiece of metal and rolling the milled metal into a cylinder. Thepressure screen can also be made by banding wires together to form acylinder, which is also referred to as wedge-wire baskets.

Pressure screens that include slotted openings can have a width of about12 μm, about 25 μm, about 50 μm, or about 75 μm to about 100 μm, about130 μm, about 150 μm, about 175 μm, about 230 μm, about 255 μm, about330 μm, about 380 μm, about 430 μm, about 500 μm, or more. In someexamples, the pressure screen can include slotted openings having awidth of about 10 μm, about 30 μm, about 50 μm, about 75 μm, about 100μm, about 125 μm, or about 150 μm to less than 250 μm, less than 300 μm,less than 350 μm, less than 400 μm, less than 450 μm, or less than 500μm.

In other examples, the separator 116 can be or include one or more fiberfilters. In some examples, the separator 116 can be a single fiberfilter. In other examples, the separator 116 can be a single fiberfilter or two or more fiber filters. In some examples, the separator 116can be or include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or more fiber filters.In other examples, the separator 116 can be a single fiber filter or twoor more fiber filters and can be free of or otherwise exclude anycentrifuge, any pressure screen, any paddle screen, or any combinationof a centrifuge, pressure screen, and paddle screen. In some examples,the separator 116 can be or include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, ormore fiber filters and can be free of or otherwise exclude anycentrifuge, any pressure screen, any paddle screen, or any combinationof a centrifuge, pressure screen, and paddle screen. In another example,the separator 116 can be a single fiber filter or two or more fiberfilters and can be free of or otherwise exclude any pressure screen,centrifuge, paddle screen, rotary drum screen, rotary vacuum drumfilter, brush strainer, vibratory separator, centrifugal screener,linear motion screen, and vacuum deck screen. In some examples, theseparator 116 can be or include 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, or morefiber filters and can be free of or otherwise exclude any pressurescreen, centrifuge, paddle screen, rotary drum screen, rotary vacuumdrum filter, brush strainer, vibratory separator, centrifugal screener,linear motion screen, and vacuum deck screen. As such, in at least oneexample, the whole stillage in line 115 can be separated into the fiberrich product via line 117 and the filtrate via line 119 with only one ortwo or more fiber filters.

The whole stillage can be introduced, e.g., pumped, into a filter sleeveof the fiber filter. The filter sleeve can have hole sizes or openingsof about 12.7 μm, about 25.4 μm, about 50.8 μm, or about 76.2 μm toabout 101.6 μm, about 127 μm, about 152.4 μm, about 177.8 μm, about 230μm, about 255 μm, about 330 μm, about 380 μm, about 430 μm, about 500μm, or more. In another example, the filter sleeve can have hole sizesor openings of about 10 μm, about 12 μm, about 25 μm, about 50 μm, orabout 75 μm to about 100 μm, about 130 μm, about 150 μm, about 175 μm,about 230 μm, about 255 μm, about 330 μm, about 380 μm, about 430 μm,about 500 μm, or more. In some examples, the filter sleeve can have holesizes or openings of about 10 μm, about 30 μm, about 50 μm, about 75 μm,about 100 μm, about 125 μm, or about 150 μm to less than 250 μm, lessthan 300 μm, less than 350 μm, less than 400 μm, less than 450 μm, orless than 500 μm.

The filter sleeve can be vibrated, e.g., at high frequency. For example,vibration of the filter sleeve can be accomplished by (1) tensioning thefilter sleeve with a pair of springs, (2) rotating a high speed rotordisposed inside the filter sleeve that can induce pulsed waves in thewhole stillage, or (3) a combination thereof. The rotor can include oneor more flights that can push or otherwise urge solids toward a sludgedischarge at the end of the fiber filter. For example, the rotor caninclude straight paddles with ribbon flighting that can direct solidstoward the discharge. The pulsing and/or vibrations can also force orotherwise urge the filtered liquid through the filter sleeve. The filtersleeve can be made of one or more polymer fabrics. The polymer can be orinclude, but is not limited to, polyester, polyether ether ketone(PEEK), or other suitable polymers. The polymer fabric can be a wovenpolymer fabric. Any type of weave can be used to produce a filter sleevecomposed of a woven polymer fabric. Illustrative types of weaves caninclude plain weave, twill weave, satin weave, basket weave, leno weave,and mock leno weave. The filter sleeve can be formed by connectingopposing edges of a filter sleeve by a lap or double hook joint. Onesuitable fiber filter can include the fiber filter discussed anddescribed in U.S. Pat. No. 6,117,321. In some examples, the fiber filtercan include a filtering body that includes a filter unit. The filterunit can include, but is not limited to, a flexible filtering sleeve anda rotor disposed within the flexible filtering sleeve. The rotor can beconfigured to pulse a fluid radially outwardly against the filteringsleeve. The filtering sleeve can be assembled or otherwise located onthe filtering body via one or more supports. The one or more supportscan be elastic and can permit the filtering sleeve to expand andcontract along a longitudinal axis thereof. The one or more supports canbe adjusted and tensioned by one or more adjustment devices locatedoutside of the flow of a filtrate. Some commercially available fiberfilters can include, but are not limited to, the FF 6, the FF 12, andthe FF 30, available from Vincent Corporation.

In other examples, the separator 116 can be or include one or morepaddle screens. In some examples, the separator 116 can be a singlepaddle screen. In other examples, the separator 116 can be a singlepaddle screen or two or more paddle screens. In other examples, theseparator 116 can be a single paddle screen or two or more paddlescreens and can be free of or otherwise exclude any centrifuge, anypressure screen, and fiber filter, or any combination of a centrifuge,pressure screen, and fiber filter. In another example, the separator 116can be a single paddle screen or two or more paddle screens and can befree of or otherwise exclude any pressure screen, centrifuge, fiberfilter, rotary drum screen, rotary vacuum drum filter, brush strainer,vibratory separator, centrifugal screener, linear motion screen, andvacuum deck screen. As such, in at least one example, the whole stillagein line 115 can be separated into the fiber rich product via line 117and the filtrate via line 119 with only one or two or more paddlescreens.

The paddle screen can include a screen that can include openings ofabout 12.7 μm, about 25.4 μm, about 50.8 μm, or about 76.2 μm to about101.6 μm, about 127 μm, about 152.4 μm, about 177.8 μm, about 230 μm,about 255 μm, about 330 μm, about 380 μm, about 430 μm, about 500 μm, ormore. In another example, the screen can have openings of about 12 μm,about 25 μm, about 50 μm, or about 75 μm to about 100 μm, about 130 μm,about 150 μm, about 175 μm, about 230 μm, about 255 μm, about 330 μm,about 380 μm, about 430 μm, about 500 μm, or more. In some examples, thescreen can have openings of about 10 μm, about 30 μm, about 50 μm, about75 μm, about 100 μm, about 125 μm, or about 150 μm to less than 250 μm,less than 300 μm, less than 350 μm, less than 400 μm, less than 450 μm,or less than 500 μm. A commercially available paddle screen can include,but is not limited to, the FQ-PS32 Paddle Screen available fromFluid-Quip, Inc.

In other examples, the separator 116 can be or include one or morerotary drum screens. In some examples, the separator 116 can be orinclude a single rotary drum screen. In other examples, the separator116 can be or include a single rotary drum screen or two or more rotarydrum screens. In other examples, the separator 116 can be or include asingle rotary drum screen or two or more rotary drum screens and can befree of or otherwise exclude any pressure screen, centrifuge, paddlescreen, fiber filter, rotary vacuum drum filter, brush strainer,vibratory separator, centrifugal screener, linear motion screen, andvacuum deck screen. As such, in at least one example, the whole stillagein line 115 can be separated into the fiber rich product via line 117and the filtrate via line 119 with only one or two or more rotary drumscreens.

The rotary drum screen can include a filter element or screen havingopenings of about 10 μm, about 25 μm, about 50 μm, or about 75 μm toabout 100 μm, about 130 μm, about 150 μm, about 175 μm, about 230 μm,about 255 μm, about 330 μm, about 380 μm, about 430 μm, about 500 μm,about 700 μm, about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, ormore. In some examples, the rotary drum screen can include openings ofabout 10 μm, about 30 μm, about 50 μm, about 75 μm, about 100 μm, about125 μm, or about 150 μm to less than 250 μm, less than 300 μm, less than350 μm, less than 400 μm, less than 450 μm, or less than 500 μm. Acommercially available rotary drum screen can include, but is notlimited to, the LIQUI-FUGE® LFS rotary drum screen available fromVulcan.

In other examples, the separator 116 can be or include one or more brushstrainers. In some examples, the separator 116 can be or include asingle brush strainer. In other examples, the separator 116 can be orinclude a single brush strainer or two or more brush strainers. In otherexamples, the separator 116 can be or include a single brush strainer ortwo or more brush strainers and can be free of or otherwise exclude anypressure screen, centrifuge, paddle screen, fiber filter, rotary drumscreen, rotary vacuum drum filter, vibratory separator, centrifugalscreener, linear motion screen, and vacuum deck screen. As such, in atleast one example, the whole stillage in line 115 can be separated intothe fiber rich product via line 117 and the filtrate via line 119 withonly one or two or more brush strainers. The brush strainer can includea casing surrounding a filter element or perforated strainer cylinder,through which the liquid can flow through. Particles suspended in thewhole stillage can be held back in the cylinder and forced downward byrotating brushes mounted on a shaft.

The filter element or perforated strainer cylinder can have openings ofabout 10 μm, about 25 μm, about 50 μm, or about 75 μm to about 100 μm,about 130 μm, about 150 μm, about 175 μm, about 230 μm, about 255 μm,about 330 μm, about 380 μm, about 430 μm, about 500 μm, about 700 μm,about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, or more. In someexamples, the perforated strainer cylinder can include openings of about10 μm, about 30 μm, about 50 μm, about 75 μm, about 100 μm, about 125μm, or about 150 μm to less than 250 μm, less than 300 μm, less than 350μm, less than 400 μm, less than 450 μm, or less than 500 μm. Acommercially available brush strainer can include, but is not limitedto, the W-SIL self-cleaning brush strainer, available from Alfa Laval.

In other examples, the separator 116 can be or include one or morerotary vacuum drum filters. In some examples, the separator 116 can beor include a single rotary vacuum drum filter. In other examples, theseparator 116 can be or include a single rotary vacuum drum filter ortwo or more rotary vacuum drum filters. In other examples, the separator116 can be or include a single rotary vacuum drum filter or two or morerotary vacuum drum filters and can be free of or otherwise exclude anypressure screen, centrifuge, paddle screen, fiber filter, rotary drumscreen, brush strainer, vibratory separator, centrifugal screener,linear motion screen, and vacuum deck screen. As such, in at least oneexample, the whole stillage in line 115 can be separated into the fiberrich product via line 117 and the filtrate via line 119 with only one ortwo or more rotary vacuum drum filters.

The rotary vacuum drum filter can include a vacuum pump, a filtratepump, and a vacuum/filtrate receiver. The rotary vacuum drum filter canalso include feed and/or drain pumps and pre-coat or chemical preptanks. The drum can rotate while partially submerged in the wholestillage. A vacuum can draw liquid through the filter element or screen,e.g., a cloth or fabric filter element on the drum surface which retainsthe solids. The vacuum can pull a gas, e.g., air, through the cake andremove moisture as the drum rotates. The filter element can haveopenings of about 10 μm, about 25 μm, about 50 μm, or about 75 μm toabout 100 μm, about 130 μm, about 150 μm, about 175 μm, about 230 μm,about 255 μm, about 330 μm, about 380 μm, about 430 μm, about 500 μm,about 700 μm, about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, ormore. In some examples, the filter medium can include openings of about10 μm, about 30 μm, about 50 μm, about 75 μm, about 100 μm, about 125μm, or about 150 μm to less than 250 μm, less than 300 μm, less than 350μm, less than 400 μm, less than 450 μm, or less than 500 μm. Acommercially available rotary vacuum drum filter can include, but is notlimited to, the vacuum drum rotary filters available fromKomline-Sanderson.

In other examples, the separator 116 can be or include one or morevibratory separators. In some examples, the separator 116 can be orinclude a single vibratory separator. In other examples, the separator116 can be or include a single vibratory separator or two or morevibratory separators. In other examples, the separator 116 can be orinclude a single vibratory separator or two or more vibratory separatorsand can be free of or otherwise exclude any pressure screen, centrifuge,paddle screen, fiber filter, rotary drum screen, brush strainer, rotaryvacuum drum filter, centrifugal screener, linear motion screen, andvacuum deck screen. As such, in at least one example, the whole stillagein line 115 can be separated into the fiber rich product via line 117and the filtrate via line 119 with only one or two or more vibratoryseparators.

The vibratory separator can vibrate, e.g., about its center of mass. Thevibration can be induced by eccentric weights on the upper and lowerends of a motion-generator shaft. The vibratory separator can includeone or more filter elements, e.g., screen decks, e.g., 1, 2, 3, 4, ormore filter elements. The filter element, e.g., screen decks, can haveopenings of about 10 μm, about 25 μm, about 50 μm, or about 75 μm toabout 100 μm, about 130 μm, about 150 μm, about 175 μm, about 230 μm,about 255 μm, about 330 μm, about 380 μm, about 430 μm, about 500 μm,about 700 μm, about 900 μm, about 1 mm, about 1.5 mm, about 2 mm, ormore. In some examples, the filter elements can include openings ofabout 10 μm, about 30 μm, about 50 μm, about 75 μm, about 100 μm, about125 μm, or about 150 μm to less than 250 μm, less than 300 μm, less than350 μm, less than 400 μm, less than 450 μm, or less than 500 μm. Somecommercially available vibratory separators can include, but are notlimited to, the VIBRO-ENERGY® Round Separators, the MX Separators, andthe Super MX Separators, available from SWECO, Inc.

In other examples, the separator 116 can be or include one or morecentrifugal screeners. In some examples, the separator 116 can be orinclude a single centrifugal screener. In other examples, the separator116 can be or include a single centrifugal screener or two or morecentrifugal screeners. In other examples, the separator 116 can be orinclude a single centrifugal screener or two or more centrifugalscreeners and can be free of or otherwise exclude any pressure screen,centrifuge, paddle screen, fiber filter, rotary drum screen, brushstrainer, rotary vacuum drum filter, vibratory separator, linear motionscreen, and vacuum deck screen. As such, in at least one example, thewhole stillage in line 115 can be separated into the fiber rich productvia line 117 and the filtrate via line 119 with only one or two or morecentrifugal screeners.

The whole stillage can be introduced to an inlet and redirected into acylindrical sifting chamber via a feed screw. Helical paddles can berotated within the chamber to propel the whole stillage against ascreen, while the resultant, centrifugal force on the particles canaccelerate the particles through apertures in the screen. The rotatingpaddles, which do not contact the screen, can breakup soft agglomerates.Over-sized particles and trash can be ejected via an oversize dischargespout. The screen can have openings of about 10 μm, about 25 μm, about50 μm, or about 75 μm to about 100 μm, about 130 μm, about 150 μm, about175 μm, about 230 μm, about 255 μm, about 330 μm, about 380 μm, about430 μm, about 500 μm, about 700 μm, about 900 μm, about 1 mm, about 1.5mm, about 2 mm, or more. In some examples, the screen can includeopenings of about 10 μm, about 30 μm, about 50 μm, about 75 μm, about100 μm, about 125 μm, or about 150 μm to less than 250 μm, less than 300μm, less than 350 μm, less than 400 μm, less than 450 μm, or less than500 μm. A commercially available centrifugal screener can include, butis not limited to, the CENTRI-SIFTER™, available from Kason Corporation.

In other examples, the separator 116 can be or include one or morelinear motion screens. In some examples, the separator 116 can be orinclude a single linear motion screen. In other examples, the separator116 can be or include a single linear motion screen or two or morelinear motion screens. In other examples, the separator 116 can be orinclude a single linear motion screen or two or more linear motionscreens and can be free of or otherwise exclude any pressure screen,centrifuge, paddle screen, fiber filter, rotary drum screen, brushstrainer, rotary vacuum drum filter, vibratory separator, centrifugalscreener, and vacuum deck screen. As such, in at least one example, thewhole stillage in line 115 can be separated into the fiber rich productvia line 117 and the filtrate via line 119 with only one or two or morelinear motion screens.

The whole stillage can be introduced to the linear motion screener,which can include an angled filter element, e.g., screen. The filterelement can be at an angle of about +10° to about −15° relative tohorizontal. The filter element or screen can have openings of about 10μm, about 25 μm, about 50 μm, or about 75 μm to about 100 μm, about 130μm, about 150 μm, about 175 μm, about 230 μm, about 255 μm, about 330μm, about 380 μm, about 430 μm, about 500 μm, about 700 μm, about 900μm, about 1 mm, about 1.5 mm, about 2 mm, or more. In some examples, thefilter element or screen can include openings of about 10 μm, about 30μm, about 50 μm, about 75 μm, about 100 μm, about 125 μm, or about 150μm to less than 250 μm, less than 300 μm, less than 350 μm, less than400 μm, less than 450 μm, or less than 500 μm. A commercially availablelinear motion screener can include, but is not limited to, the linearmotion screeners available from Tinsley Company.

In other examples, the separator 116 can be or include one or morevacu-deck screens. In some examples, the separator 116 can be or includea single vacu-deck screen. In other examples, the separator 116 can beor include a single vacu-deck screen or two or more vacu-deck screens.In other examples, the separator 116 can be or include a singlevacu-deck screen or two or more vacu-deck screens and can be free of orotherwise exclude any pressure screen, centrifuge, paddle screen, fiberfilter, rotary drum screen, brush strainer, rotary vacuum drum filter,vibratory separator, centrifugal screener, and linear motion screener.As such, in at least one example, the whole stillage in line 115 can beseparated into the fiber rich product via line 117 and the filtrate vialine 119 with only one or two or more vacu-deck screens.

The vacu-deck screen can include one or more filter elements or screensthat can have openings of about 10 μm, about 25 μm, about 50 μm, orabout 75 μm to about 100 μm, about 130 μm, about 150 μm, about 175 μm,about 230 μm, about 255 μm, about 330 μm, about 380 μm, about 430 μm,about 500 μm, about 700 μm, about 900 μm, about 1 mm, about 1.5 mm,about 2 mm, or more. In some examples, the filter element or screen caninclude openings of about 10 μm, about 30 μm, about 50 μm, about 75 μm,about 100 μm, about 125 μm, or about 150 μm to less than 250 μm, lessthan 300 μm, less than 350 μm, less than 400 μm, less than 450 μm, orless than 500 μm. A commercially available vacu-deck screen can include,but is not limited to, the vacu-deck screens available from TinsleyCompany.

The separator 116, e.g., a pressure screen and/or a fiber filter, canprocess or filter the whole stillage at a rate of about 94.6 liters perminute, about 379 liters per minute, about 946 liters per minute, orabout 1,890 liters per minute to about 2,840 liters per minute, about3,790 liters per minute, about 4,730 liters per minute, about 5,680liters per minute, about 6,620 liters per minute, about 7,570 liters perminute, about 11,000 liters per minute, about 15,000 liters per minute,about 19,000 liters per minute, about 22,500 liters per minute, about26,500 liters per minute, or about 30,500 liters per minute. In oneexample, the separator, e.g., a pressure screen and/or a fiber filter,can process or filter the whole stillage at a rate of at least 1,890liters per minute, at least 2,460 liters per minute, at least 3,030liters per minute, at least 3,600 liters per minute, at least 3,970liters per minute, at least 4,540 liters per minute, at least 4,920liters per minute, or at least 5,300 liters per minute to about 5,680liters per minute, about 6,620 liters per minute, about 7,570 liters perminute, about 12,000 liters per minute, about 20,000 liters per minute,about 26,000 liters per minute, or about 30,500 liters per minute.

In some examples, if the separator 116 is or includes one or more fiberfilters, the filtrate via line 119 can contains less solids as comparedto if the separator 116 includes one or more centrifuges, one or morepressure screens, one or more paddle screens, or any combinationthereof. In other examples, if the separator 116 includes only one ormore fiber filters, i.e., does not include a centrifuge, a pressurescreen, a paddle screen, or other separator, the filtrate via line 119can contain less solids as compared to if the separator includes acentrifuge, a pressure screen, a paddle screen, or other separator, butnot a fiber filter.

The filtrate can be transferred via line 119 from the separator 116 toone or more separators 120 (e.g., a two phase separator such as a nozzlecentrifuge, or a three phase separator such as a TRICANTER®, availablefrom Flottweg). As shown, the separator 120 can be a three phaseseparator and can separate or otherwise produce a protein rich productvia line 122, an oil product via line 123, and a clarified stillage thatcan be free from or have a reduced oil content via line 121. In otherexamples, the separator 120 can be a centrifuge that can separate orotherwise produce the protein rich product via line 122 and a clarifiedstillage via line 121 from the filtrate in line 119. The separator 120can be provided with washing capabilities so that water, along with thefiltrate, can be supplied to the separator 120. If the separator 120includes a centrifuge, the additional water can facilitate separation ofthe filtrate into the protein rich product and the clarified stillage.The heavier protein can separate from the lighter components and can beremoved as an underflow containing the protein rich product, whereas thelighter components, which can include oil and starch, can be removed asan overflow containing the clarified stillage. In other examples, theseparator 120 can also include or can be replaced with a cycloneseparation apparatus or other device to separate the filtrate portioninto the protein rich product and the clarified stillage.

The protein rich product can be dewatered or otherwise dried such thatwater can be removed from the protein rich product to produce a driedprotein product. The protein rich product via line 122 can betransferred from the centrifuge 120 to one or more dryers 124. In someexamples, as depicted in FIG. 1, the protein rich product via line 122can be transferred to the dryer 124 to reduce the amount of water and/orotherwise dry the protein rich product to produce the dried proteinproduct. The dried protein product via line 126 can be transferred fromthe dryer 124 to one or more storage containers 128. In some examples,the separated water portion or filtrate from the dryer 124 can berecycled back or otherwise transferred to the fermenter 108 forliquefaction and/or fermentation. The dried protein product can includeless water than the protein rich product.

The dryer 124 can be or include one or more centrifuges (e.g., adecanter centrifuge), one or more ring dryers (e.g., P-ring dryers), oneor more flash dryers, one or more fluid bed dryers, one or more heatedair dryers, one or more heaters, one or more steam dryers (e.g., steamring dryers, steam flash dryers, and/or steam tube dryers), one or morerotary dryers, one or more steam and rotary dryers (e.g., Swiss Combi'secoDRY™ drying system), one or more superheated steam dryers, one ormore spray dryers, one or more vacuum filtration dryers, one or moreother drying devices, or any combination thereof to remove water andproduce the dried protein product.

The dried protein product in line 126 can be or include high proteincorn meal. In some examples, the dried protein product can be used asfish feed, shrimp feed, crab feed, other aquaculture feeds, pig feed,cattle feed, chicken feed, or other livestock feed. The dried proteinproduct can include about 35 wt %, about 40 wt %, or about 45 wt % toabout 50 wt %, about 55 wt %, about 60 wt %, about 70 wt %, about 80 wt%, or greater of protein on a dry matter basis. For example, the driedprotein product can include about 35 wt % to about 80 wt %, about 35 wt% to about 70 wt %, about 35 wt % to about 60 wt %, about 35 wt % toabout 55 wt %, about 35 wt % to about 50 wt %, about 45 wt % to about 80wt %, about 45 wt % to about 70 wt %, about 45 wt % to about 60 wt %,about 45 wt % to about 55 wt %, or about 45 wt % to about 50 wt % ofprotein on a dry matter basis.

The clarified stillage via line 121, whether recovered from a threephase separator or a two phase separator, can be transferred via line121 to one or more evaporators 140. The clarified stillage can bedewatered, i.e., water can be removed from the clarified stillage, toproduce an evaporated clarified stillage. For example, the evaporator140 can gasify at least a portion of the water in the clarified stillageto produce the evaporated clarified stillage.

In some examples, the evaporated clarified stillage via line 142 can betransferred from the evaporator 140 to one or more additionalevaporators 150. For example, if the separator 120 is or includes athree phase separator, the evaporated clarified stillage via line 142can be introduced to the additional evaporator 150. In other examples,the evaporated clarified stillage via line 141 can be transferred fromthe evaporator 140 to one or more oil recovery centrifuges 145. Forexample, if the separator 120 is or includes a centrifuge, theevaporated clarified stillage can be introduced to the oil recoverycentrifuge 145 to separate and produce an oil product and an evaporatedclarified stillage with reduced oil, also referred to as a stillage withreduced oil. One or more oil products via line 146 can be transferredfrom the oil recovery centrifuge 145 to one or more storage containers148. The oil product can include a mixture of typical fatty acids foundin corn oil. In some examples, the final recovered oil product can beabout 30 wt %, about 40 wt %, about 45 wt % to about 50 wt %, about 60wt %, or about 70 wt % of the total corn oil in the corn (e.g., cornkernels and/or other corn pieces). The oil recovery centrifuge 145 canfunction at a higher capacity because the evaporated clarified stillage,which can be subjected to the oil recovery centrifuge 145, can includeless water and less protein than the clarified stillage. It should benoted that the evaporated clarified stillage in line 142, when theseparator 120 is or includes a three phase separator and produces theoil product via line 123, can also be introduced to the oil recoverycentrifuge 145 to produce additional oil product via line 146, providedless than all of the oil in the filtrate was separated by the separator120.

The stillage with reduced oil via line 143 from the oil recoverycentrifuge 145 can be introduced into one or more evaporators 150. Thestillage with reduced oil can be further dewatered or dried in theevaporator 150 where water or other liquids can be further evaporatedfrom the stillage with reduced oil to produce a syrup. The syrup caninclude, but is not limited to, minerals, sugars, starches, proteins,fibers, other components contained in water, or any mixture thereof. Thesyrup can be used alone or combined with other components or stream inthe separation system 100 to produce various types of products. Forexample, the syrup via line 151 from the evaporator 150 can betransferred without any further processing to one or more storagecontainers 152 and can be used or sold as an independent product. Inother examples, the syrup via line 153, 157, or 159 can be transferredfrom the evaporator 150 to one of several portions of the separationsystem 100 and combined with the fiber rich product, as will be furtherdiscussed and described below.

While the clarified stillage and the stillage with reduced oil can besubjected to the evaporators 140, 150, it should be understood that thenumber of evaporators and sets thereof can be varied depending on theparticular application, conditions, and desired product compositions. Insome configurations, each evaporator 140, 150 can be one evaporator or aplurality of evaporators, such as 2, 3, 4, 5, 6, or more evaporatorscoupled in series and in fluid communication with one another. Forexample, the evaporator 140 can have three or more evaporators and theevaporator 150 can also have three or more evaporators.

The fiber rich product via line 117 from the separator 116 can betransferred without any further processing via line 136 to one or morestorage containers 138 and referred to as a wet fiber rich product thatcan be used or sold as an independent product. Alternatively, the fiberrich product via lines 117 and 154 can be transferred to one or moredryers 160. The fiber rich product can be further dried or dewatered bythe dryer 160 to provide a dried fiber rich product that can betransferred via line 162 to one or more storage containers 164.

The dryer 160 can be or include one or more centrifuges (e.g., adecanter centrifuge), one or more ring dryers (e.g., P-ring dryers), oneor more flash dryers, one or more fluid bed dryers, one or more heatedair dryers, one or more heaters, one or more steam dryers (e.g., steamring dryers, steam flash dryers, and/or steam tube dryers), one or morerotary dryers, one or more steam and rotary dryers (e.g., Swiss Combi'secoDRY drying system), one or more superheated steam dryers, one or morespray dryers, one or more vacuum filtration dryers, one or more otherdrying devices, or any combination thereof to remove water and producethe dried protein product.

In other examples, the fiber rich product and the syrup can be combinedtogether. For example, the fiber rich product via line 117 and the syrupvia line 153 from the evaporator 150 can be combined and mixed in line154 or other processing unit to produce a wet fiber rich product withsyrup that can be transferred via line 155 to one or more storagecontainers 156.

In some examples, the wet fiber rich product with syrup via line 154 canbe transferred to the dryer 160. The wet fiber rich product with syrupcan be further dried or dewatered by dryer 160 to provide a dried fiberrich product with syrup that can be transferred via line 165 to one ormore storage containers 168. The dried fiber rich product with syrup canbe used or sold as an independent product.

Alternatively, in other examples, the fiber rich product and the syrupcan be combined together in the dryer 160. For example, the fiber richproduct via lines 117 and 154 and the syrup via line 157 from theevaporator 150 can be combined and mixed in dryer 160 to produce the wetfiber rich product with syrup that can be dried in the dryer 160 toproduce the dried fiber rich product with syrup. The dried fiber richproduct with syrup can be transferred from the dryer 160 via line 165 tothe storage container 168. In other examples, the dried fiber richproduct via line 162 from the dryer 160 and the syrup via line 159 fromthe evaporator 150 can be combined and mixed in line 167 or otherprocessing unit to produce the dried fiber rich product with syrup thatcan be transferred via line 167 to the storage container 168.

FIG. 2 depicts a schematic view of an illustrative system 200 forproducing ethanol from a fiber product recovered from a whole stillage,according to one or more embodiments. A whole stillage via line 215 canbe introduced to one or more separators 216. The whole stillage can beproduced in the same or substantially the same way as the whole stillagein line 115 discussed and described above with reference to FIG. 1. Theground corn that can be processed to produce a fermentation mash thatthe whole stillage can be separated from can be ground with one or moredisk mill fiberizers. The whole stillage can be contacted or otherwiseprocessed in the separator 216 to separate or otherwise produce a fiberrich product via line 217 and a filtrate via line 219. The separator 216can be or include any one or more of the separators 116 discussed anddescribed above with reference to FIG. 1. For example, the separator 216can be or include, but is not limited to, one or more pressure screens,one or more centrifuges (e.g., a filtration centrifuge such as thosediscussed and described in U.S. Pat. Nos. 8,813,973 and 8,778,433), oneor more paddle screens, one or more fiber filters, one or more rotarydrum screens, one or more rotary vacuum drum filters, one or more brushstrainers, one or more vibratory separators, one or more centrifugalscreeners, one or more linear motion screens, one or more vacu-deckscreens, or any combination thereof. In some examples, the separator 216can be or include one or more fiber filters. In other examples, theseparator 216 can be or include one or more paddle screens.

In some examples, the filtrate in line 219 can be processed in the sameor substantially the same manner as the filtrate in line 119 discussedand described above with reference to FIG. 1. The fiber rich product vialine 217 can be introduced to one or more pretreatment vessels 224 toproduce a pretreated fiber rich product via line 226. The pretreatmentvessel 224 can be or include, for example, a slurry tank or a pressurevessel. The pretreatment vessel 224 can disrupt the structure of thefiber rich product to produce a fiber rich product that can be morereadily accessible and digestible to hydrolysis with an enzyme, e.g., acellulose enzyme. For example, hemicellulose can be converted tooligomers, xylose, and/or arabinose and the cellulose and/orhemicellulosic oligomers can be made more accessible and digestible tothe cellulase enzyme.

In some examples, one or more acids and/or one or more bases via line222 can be mixed, blended, combined, or otherwise contacted with thefiber rich product within the pretreatment vessel 224. In some examples,the fiber rich product and the acid and/or base can be heated to atemperature of about 50° C., about 75° C., or about 100° C. to about115° C., about 125° C., about 150° C., about 175° C., about 200° C., orabout 225° C. The fiber rich product and the acid and/or base can beheated for a time of about 10 minutes, about 30 minutes, or about 1 hourto about 2 hours, about 5 hours, or about 10 hours. Illustrative acidsthat can be contacted with the fiber rich product can include, but arenot limited to, sulfuric acid, nitric acid, hydrochloric acid,phosphoric acid, strong acid resins, acetic acid, citric acid,trichloroacetic acid, or any mixture thereof. Illustrative bases thatcan be contacted with the fiber rich product can include, but are notlimited to, ammonium hydroxide, potassium hydroxide, sodium hydroxide,calcium hydroxide, magnesium hydroxide, strong base resins, sodiumcarbonate, potassium carbonate, lime, or any mixture thereof. In someexamples, the fiber rich product contacted with the acid and/or base canalso be irradiated, e.g., microwaves and/or radio waves. In someexamples, the fiber rich product, without being contacted with an acidor a base, can be irradiated, e.g., microwaves and/or radio waves. Insome examples, the fiber rich product can be subjected to steamexplosion, e.g., contact with steam at a temperature of about 160° C. toabout 260° C., under a pressure of about 0.7 Mpa to about 5 Mpa, for atime of about 1 minute to about 20 minutes.

Other processes that can be used to produce the pretreated fiber richproduct in lieu of or in addition to an acid and/or a base can include,but are not limited to, ionic liquid pretreatment; liquid hot water(LHW) pre-treatment; supercritical water; steam explosion; ammonia fiberexplosion (AFEX); carbon dioxide explosion; contact withheteropolyacids, e.g., H₅BW₁₂O₄₀; ozonolysis; organosolvation treatmentwith an organic solvent such as acetone, methanol, ethanol, phenol,ethylene glycol, tetrahydrofuran, and/or tetrahydrofurfuryl; or anycombination thereof.

The pretreated fiber rich product via line 226 can be introduced to oneor more saccharification vessels 232. One or more enzymes via line 228can also be introduced to the saccharification vessel 232. Thepretreated fiber rich product can be contacted under conditionssufficient to produce a saccharification mash that can be recovered vialine 236. During saccharification, the pretreated fiber rich product canbe cooled and one or more enzymes, e.g., glucoamylase, can be added tohydrolyze maltodextrins and oligosaccharides into single glucose sugarmolecules.

Illustrative enzymes can include, but are not limited to, one or morecellulases, one or more hemicellulases, or a mixture thereof. In someexamples a cellulase and a hemicellulase can be used. The cellulase caninclude, but is not limited to, exo-glucanases, endo-gluconases,beta-glucosidase, and potentially some xylanase activity. Thehemicellulase can include a number of different activities such asexo-xylanase, endo-xylanase, arabinose, esterase, and proteases. Theseenzyme mixtures are available commercially from Novozymes (FranklintonN.C.) and DuPont (Wilmington Del.). Commercially available enzymes thatcan be used can include, but are not limited to, ACCELLERASE® Trio;ACCELLERASE® 1500; ACCELLERASE® BG, OPTIMASH®, and SPEZYME® CP(available from Dupont); CELLUCLAST® 1.5 L; CELLIC® CTec2; CELLIC®CTec3, CELLIC® CTec4, HTec1, HTec2, HTec3 (available from Novozymes);ROHAMENT® CL, ROHAMENT® CEP, ROHALASE® BXL, ROHALASE® SEP (availablefrom AB Enzymes); SZM XC-150 (available from CTE-Global), and CODEXYME®4 (available from Codexis).

The saccharification mash via line 236 can be introduced to one or morefermenters 242. One or more strains of yeast, e.g., Saccharomycescerevisae, Pichia Stipitis, and/or Candida utilis, can be introduced vialine 238 to the fermenter 242 to initiate fermentation of thesaccharification mash and produce a fermented product that can includeethanol and a stillage protein product that can be recovered via line246. The yeast can ferment, metabolize, digest, or otherwise convert thesugars in the saccharification mash with yeast into ethanol and carbondioxide. The saccharification mash can be heated or otherwise maintainedat a temperature of about 28° C. to about 55° C. during thefermentation.

The fermented product via line 246 can be introduced to one or moredistillers 252 where the fermented product can be heated to vaporize atleast a portion of the ethanol. The distiller 252 can be or include, butis not limited to, one or more distillation columns, distillationtrains, one or more condensers, or other devices configured to vaporizethe ethanol and to condense the vaporized ethanol. The ethanol can bedistilled or otherwise separated from the fermented product within thedistiller 252 and recovered via line 254. The stillage protein productcan be recovered via line 256.

FIG. 3 depicts a schematic view of another illustrative system 300 forproducing ethanol from a fiber product recovered from a whole stillage,according to one or more embodiments. A whole stillage via line 315 canbe introduced to one or more separators 316. The whole stillage can beproduced in the same or substantially the same way as the whole stillagein line 315 discussed and described above with reference to FIG. 1. Thewhole stillage can be contacted or otherwise processed in the separator316 to separate or otherwise produce a fiber rich product via line 317and a filtrate via line 319. In some examples, the filtrate in line 319can be processed in the same or substantially the same manner as thefiltrate in line 119 discussed and described above with reference toFIG. 1. The fiber rich product via line 317 can be introduced to one ormore pretreatment vessels 324 to produce a pretreated fiber rich productvia line 326. The pretreatment vessel 324 can be or include, forexample, a slurry tank or a pressure vessel. The pretreatment vessel 324can disrupt the structure of the fiber rich product to produce a fiberrich product that can be more readily accessible and digestible tohydrolysis with an enzyme, e.g., a cellulose enzyme. For example,hemicellulose can be converted to oligomers, xylose, and/or arabinoseand the cellulose and/or hemicellulosic oligomers can be made moreaccessible and digestible to the cellulase enzyme.

In some examples, one or more acids and/or one or more bases via line322 can be mixed, blended, combined, or otherwise contacted with thefiber rich product within the pretreatment vessel 324. In some examples,the fiber rich product and the acid and/or base can be heated to atemperature of about 50° C., about 75° C., or about 100° C. to about115° C., about 125° C., about 150° C., about 175° C., about 200° C., orabout 225° C. The fiber rich product and the acid and/or base can beheated for a time of about 10 minutes, about 30 minutes, or about 1 hourto about 2 hours, about 5 hours, or about 10 hours. Illustrative acidsthat can be contacted with the fiber rich product can include, but arenot limited to, sulfuric acid, nitric acid, hydrochloric acid,phosphoric acid, or any mixture thereof. Illustrative bases that can becontacted with the fiber rich product can include, but are not limitedto, ammonium hydroxide, potassium hydroxide, sodium hydroxide, calciumhydroxide, or any mixture thereof. In some examples, the fiber richproduct and the acid and/or base can also be irradiated, e.g.,microwaves and/or radio waves. In some examples, the fiber rich productcan be subjected to steam explosion, e.g., contact with steam at atemperature of about 160° C. to about 260° C., under a pressure of about0.7 Mpa to about 5 Mpa, for a time of about 1 minute to about 20minutes.

Other processes that can be used to produce the pretreated fiber richproduct can include, but are not limited to, liquid hot water (LHW)pre-treatment; ammonia fiber explosion (AFEX); carbon dioxide explosion;contact with heteropolyacids, e.g., H₅BW₁₂O₄₀; ozonolysis;organosolvation treatment with an organic solvent such as acetone,methanol, ethanol, phenol, ethylene glycol, and/or tetrahydrofurfuryl;or any combination thereof.

The pretreated fiber rich product via line 326 can be introduced to oneor more fermenters 342. The pretreated fiber rich product can besubjected to simultaneous saccharification and fermentation (SSF) withinthe fermenter 342. For example, one or more enzymes via line 328 and oneor more yeasts rains of yeast, e.g., Saccharomyces cerevisae, PichiaSupitis, and/or Candida utilis, via line 338 can also be introduced tothe fermenter 342 to produce a fermented product. In some examples, theenzyme via line 328 and the yeast via line 338 can be introduced to thefermenter 342 at the same time. Illustrative enzymes can include, butare not limited to, one or more cellulases, one or more hemicellulases,or a mixture thereof. In some examples a cellulase and a hemicellulasecan be used. The cellulase can include, but is not limited to,exo-glucanases, endo-gluconases, beta-glucosidase, and potentially somexylanase activity. The hemicellulase can include a number of differentactivities such as exo-xylanase, endo-xylanase, arabinose, esterase, andproteases. These enzyme mixtures are available commercially fromNovozymes (Franklinton N.C.) and DuPont (Wilmington Del.).

In other examples, the enzyme via line 328 can be introduced to thefermenter 342 before the yeast via line 338. The saccharification of thepretreated fiber rich product can hydrolyze maltodextrins andoligosaccharides into single glucose sugar molecules. The fermentationof the fiber rich product and/or the saccharification mash can produceadditional ethanol and a stillage protein product that can be recoveredas the fermented product via line 346 from the fermenter 342. The fiberrich product and/or saccharification mash can be heated or otherwisemaintained at a temperature of about 28° C. to about 55° C. duringsaccharification and fermentation.

The fermented product via line 346 can be introduced to one or moredistillers 352 where the fermented product can be heated to vaporize atleast a portion of the ethanol. The distiller 352 can be or include, butis not limited to, one or more distillation columns, distillationtrains, one or more condensers, or other devices configured to vaporizethe ethanol and to condense the vaporized ethanol. The ethanol can bedistilled or otherwise separated from the fermented product within thedistiller 352 and recovered via line 354. The stillage protein productcan be recovered via line 356.

Returning to the fiber rich products in lines 217 and 317, the fiberrich products can include inorganic compounds (commonly referred to asash); structural protein; extractives such as fats and glycerol;acetate; lignin; C6 polysaccharides; C5 polysaccharides; or any mixturethereof. In some examples, the fiber rich products in lines 217 and 317can include at least 20 wt %, at least 21 wt %, at least 22 wt %, atleast 23 wt %, at least 24 wt %, at least 25 wt %, at least 26 wt %, atleast 27 wt %, at least 28 wt %, at least 29 wt %, or at least 30 wt %of C6 polysaccharides, based on a dried weight of the fiber richproducts. In some examples, the fiber rich products in lines 217 and 317can include at least 20 wt %, at least 21 wt %, at least 22 wt %, atleast 23 wt %, at least 24 wt %, at least 25 wt %, at least 26 wt %, atleast 27 wt %, at least 28 wt %, at least 29 wt %, at least 30 wt %, atleast 31 wt %, at least 32 wt %, at least 33 wt %, at least 34 wt %, atleast 35 wt %, at least 36 wt %, at least 37 wt %, at least 38 wt %, atleast 39 wt %, at least 40 wt %, at least 41 wt %, or at least 42 wt %of C5 polysaccharides, based on the dried weight of the fiber richproducts. In some examples, the fiber rich products in lines 217 and 317can include about 25 wt % to about 35 wt % of C6 polysaccharides andabout 23 wt % to about 45 wt % of C5 polysaccharides, based on the driedweight of the fiber rich products. In some examples, the fiber richproducts in lines 217 and 317 can include about 27 wt % to about 30 wt %of C6 polysaccharides and about 24 wt % to about 28 wt % of C5polysaccharides, based on the dried weight of the fiber rich products.In other examples, the fiber rich products in lines 217 and 317 caninclude about 28 wt % to about 33 wt % of C6 polysaccharides and about38 wt % to about 45 wt % of C5 polysaccharides, based on the driedweight of the fiber rich products. In some examples, the fiber richproducts in lines 217 and 317 can include at least 20 wt % to about 35wt % of C6 polysaccharides and at least 20 wt % to about 45 wt % of C5polysaccharides, based on the dried weight of the fiber rich products.

In some examples, the fiber rich products in lines 217 and 317 caninclude at least 20 wt %, at least 21 wt %, at least 22 wt %, at least23 wt %, at least 24 wt %, at least 25 wt %, at least 26 wt %, at least27 wt %, at least 28 wt %, at least 29 wt %, or at least 30 wt % of acombined amount of glucan, galactan, mannan, and starch, based on adried weight of the fiber rich products. In some examples, the fiberrich products in lines 217 and 317 can include at least 20 wt %, atleast 21 wt %, at least 22 wt %, at least 23 wt %, at least 24 wt %, atleast 25 wt %, at least 26 wt %, at least 27 wt %, at least 28 wt %, atleast 29 wt %, at least 30 wt %, at least 31 wt %, at least 32 wt %, atleast 33 wt %, at least 34 wt %, at least 35 wt %, at least 36 wt %, atleast 37 wt %, at least 38 wt %, at least 39 wt %, at least 40 wt %, atleast 41 wt %, or at least 42 wt % of a combined amount of xylan andarabinan, based on the dried weight of the fiber rich products. In someexamples, the fiber rich products in lines 217 and 317 can include about25 wt % to about 35 wt % of a combined amount of glucan, galactan,mannan, and starch and about 23 wt % to about 45 wt % of a combinedamount of xylan and arabinan, based on the dried weight of the fiberrich products. In some examples, the fiber rich products in lines 217and 317 can include about 27 wt % to about 30 wt % of a combined amountof glucan, galactan, mannan, and starch and about 24 wt % to about 28 wt% of a combined amount of xylan and arabinan, based on the dried weightof the fiber rich products. In other examples, the fiber rich productsin lines 217 and 317 can include about 28 wt % to about 33 wt % of acombined amount of glucan, galactan, mannan, and starch and about 38 wt% to about 45 wt % of a combined amount of xylan and arabinan, based onthe dried weight of the fiber rich products. In some examples, the fiberrich products in lines 217 and 317 can include at least 20 wt % to about35 wt % of a combined amount of glucan, galactan, mannan, and starch andat least 20 wt % to about 45 wt % of a combined amount of xylan andarabinan, based on the dried weight of the fiber rich products.

In some examples, the fiber rich products in lines 217 and 317 caninclude about 12 wt %, about 13 wt %, about 14 wt %, about 15 wt %,about 16 wt %, about 17 wt %, or about 18 wt % to about 19 wt %, about20 wt %, about 21 wt %, about 22 wt %, about 23 wt %, about 24 wt %, orabout 25 wt % of glucan, based on the dried weight of the fiber richproducts. In some examples, the fiber rich products in lines 217 and 317can include about 2 wt %, about 3 wt %, about 4 wt %, about 4.5 wt %, orabout 5 wt % to about 6 wt %, about 6.5 wt %, about 7 wt %, about 7.5 wt%, about 8 wt %, about 8.5 wt %, about 9 wt %, about 9.5 wt %, or about10 wt % of galactan, based on the dried weight of the fiber richproducts. In some examples, the fiber rich products in lines 217 and 317can include about 1 wt %, about 1.3 wt %, about 1.5 wt %, about 1.7 wt%, about 2 wt %, about 2.3 wt %, or about 2.5 wt % to about 2.7 wt %,about 3 wt %, about 3.3 wt %, about 3.5 wt %, about 3.7 wt %, about 4 wt%, about 4.3 wt %, about 4.5 wt %, about 4.7 wt %, or about 5 wt % ofstarch, based on the dried weight of the fiber rich products. In someexamples, the fiber rich products in lines 217 and 317 can include about10 wt %, about 12 wt %, about 14 wt %, about 16 wt %, or about 18 wt %to about 20 wt %, about 22 wt %, about 24 wt %, about 26 wt %, or about28 wt % of xylan, based on the dried weight of the fiber rich products.In some examples, the fiber rich products in lines 217 and 317 caninclude about 7 wt %, about 8 wt %, about 9 wt %, or about 10 wt % toabout 12 wt %, about 14 wt %, about 16 wt %, about 17 wt %, about 18 wt%, about 19 wt %, or about 20 wt % of arabinan, based on the driedweight of the fiber rich products. In some examples, the fiber richproducts in lines 217 and 317 can include about 12 wt % to about 22 wt %of glucan, about 11 wt % to about 28 wt % of xylan, about 2.5 wt % toabout 8 wt % of galactan, about 7 wt % to about 20 wt % of arabinan, andabout 2 wt % to about 5 wt % of starch, based on the dried weight of thefiber products. In other examples, the fiber rich products in lines 217and 317 can include about 16 wt % to about 22 wt % of glucan, about 14wt % to about 28 wt % of xylan, about 5 wt % to about 8 wt % ofgalactan, about 8 wt % to about 20 wt % of arabinan, and about 3.7 wt %to about 5 wt % of starch, based on the dried weight of the fiberproducts. In some examples, the fiber rich products in lines 217 and 317can include at least 16 wt % of glucan, at least 15 wt % of xylan, atleast 5 wt % of galactan, at least 9 wt % of arabinan, and at least 2 wt% of starch, based on the dried weight of the fiber products. In someexamples, the fiber rich products in lines 217 and 317 can include atleast 18 wt % of glucan, at least 16 wt % of xylan, at least 6 wt % ofgalactan, at least 9 wt % of arabinan, and at least 2 wt % of starch,based on the dried weight of the fiber products. In some example, thefiber rich products in lines 217 and 317 can include at least 20 wt % ofglucan, at least 20 wt % of xylan, at least 6 wt % of galactan, at least15 wt % of arabinan, and at least 2 wt % of starch, based on the driedweight of the fiber products.

In some examples, the fiber rich products in lines 217 and 317 caninclude about 10 wt %, about 13 wt %, or about 15 wt % to about 20 wt %,about 23 wt %, about 25 wt %, or about 27 wt % of structural proteinbased on a dried weight of the fiber rich products. In other examples,the fiber rich products in lines 217 and 317 can include less than 20 wt%, less than 19 wt %, less than 18 wt %, less than 17 wt %, less than 16wt %, less than 15 wt %, or less than 14 wt % of structural protein,based on a dried weight of the fiber rich products. In other examples,the fiber rich products in lines 217 and 317 can include at least 19 wt%, at least 20 wt %, at least 21 wt %, or at least 22 wt % to about 23wt %, about 24 wt %, about 25 wt %, or about 27 wt % of structuralprotein, based on a dried weight of the fiber rich product.

In some examples, the fiber rich products in lines 217 and 317 caninclude less than 1.4 wt %, less than 1.3 wt %, less than 1.2 wt %, lessthan 1.1 wt %, less than 1 wt %, less than 0.9 wt %, less than 0.8 wt %,or less than 0.7 wt % of the inorganic compounds, based on a driedweight of the fiber rich products. In some examples, the fiber richproducts in lines 217 and 317 can include less than 5 wt %, less than4.5 wt %, less than 4 wt %, less than 3.5 wt %, less than 3 wt %, lessthan 2.5 wt %, less than 2 wt %, or less than 1.7 wt % of theextractives. In some examples, the fiber rich products in lines 217 and317 can include about 1.5 wt %, about 1.7 wt %, about 2 wt %, or about2.3 wt % to about 2.7 wt %, about 3 wt %, about 3.5 wt %, or about 4 wt% of acetate, based on a dried weight of the fiber rich products. Insome examples, the fiber rich products in lines 217 and 317 can includeabout 15 wt %, about 16 wt %, about 17 wt % or about 18 wt % to about 19wt %, about 20 wt %, about 21 wt %, or about 22 wt % of lignin, based ona dried weight of the fiber rich products.

In some examples, the fiber rich products in lines 217 and 317 caninclude less than 1 wt % of the inorganic compounds, less than 2 wt % ofthe extractives, about 1.8 wt % to about 4 wt % of acetate, about 27 wt% to about 30 wt % of C6 polysaccharides, and about 24 wt % to about 28wt % of C5 polysaccharides, based on a dried weight of the fiber richproducts. In some examples, the fiber rich products in lines 217 and 317can include less than 1 wt % of the inorganic compounds, about 20 wt %to about 26 wt % of structural protein, less than 2 wt % of theextractives, about 2 wt % to about 4 wt % of acetate, about 27 wt % toabout 30 wt % of C6 polysaccharides, and about 24 wt % to about 28 wt %of C5 polysaccharides, based on a dried weight of the fiber richproducts. In other examples, the fiber rich products in lines 217 and317 can include less than 1 wt % of the inorganic compounds, less than 2wt % of the extractives, about 1.8 wt % to about 4 wt % of acetate,about 20 wt % to about 25 wt % of structural protein, about 17 wt % toabout 22 wt % of lignin, about 27 wt % to about 30 wt % of C6polysaccharides, and about 24 wt % to about 28 wt % of C5polysaccharides, based on a dried weight of the fiber rich products.

In some examples, the fiber rich products in lines 217 and 317 caninclude less than 1 wt % of inorganic compounds, less than 1 wt % ofextractives, about 1.5 wt % to about 3 wt % of acetate, about 28 wt % toabout 33 wt % of C6 polysaccharides, and about 38 wt % to about 45 wt %of C5 polysaccharides, based on a dried weight of the fiber richproducts. In other examples, the fiber rich products in lines 217 and317 can include less than 1 wt % of inorganic compounds, about 10 wt %to about 16 wt % of structural protein, less than 1 wt % of extractives,about 1.5 wt % to about 3 wt % of acetate, about 28 wt % to about 33 wt% of C6 polysaccharides, and about 38 wt % to about 45 wt % of C5polysaccharides, based on a dried weight of the fiber rich products. Inother examples, the fiber rich products in lines 217 and 317 can includeless than 1 wt % of inorganic compounds, about 10 wt % to about 16 wt %of structural protein, less than 1 wt % of extractives, about 1.5 wt %to about 3 wt % of acetate, about 17 wt % to about 22 wt % of lignin,about 28 wt % to about 33 wt % of C6 polysaccharides, and about 38 wt %to about 45 wt % of C5 polysaccharides, based on a dried weight of thefiber rich products.

The dried weight or solids weight of the fiber rich products, thestillage protein products, and other products can be determined viastandard tests used in the industry. For example, the dried weight orsolids weight of the fiber rich product, the stillage protein product,or other product can be determined according to the National RenewableEnergy Laboratory (NREL) test, “Determination of Total Solids in Biomassand Total Dissolved Solids in Liquid Process Samples”, Version 2008. Theamount of the inorganic compounds, structural protein, extractives,acetate, lignin, C6 polysaccharides, and C5 polysaccharides in the fiberrich products can also be determined via standard tests used in theindustry. For example, the amount of inorganic compounds in the fiberrich products can be determined according to the NREL Chemical Analysisand Standard Testing Procedure, “Determination of Ash in Biomass”,Version 2005. The amount of structural protein in the fiber richproducts can be determined according to the NREL Chemical Analysis andStandard Testing Procedure, “Determination of Protein Content inBiomass”, Version 2008. The amount of extractives in the fiber richproducts can be determined according to the NREL Chemical Analysis andStandard Testing Procedure, “Determination of Extractives in Biomass”,Version 2005. The amount of acetate, lignin, C6 polysaccharides, and C5polysaccharides in the fiber rich products can be determined accordingto the NREL Chemical Analysis and Standard Testing Procedure,“Determination of Structural Carbohydrates and Lignin in Biomass”,Version 2012. The amount of starch in the fiber rich products can bedetermined according to the NREL Chemical Analysis and Standard TestingProcedure, “Determination of Starch in Solid Biomass Sample”, Version2005.

Other standardized tests that can be used to determine the amount of C6polysaccharides, C5 polysaccharides, and starch can also be used. Forexample, rather than using the NREL Chemical Analysis and Standard TestProcedure, “Determination of Structural Carbohydrates and Lignin inBiomass”, Version 2012 to determine the amounts of any C6polysaccharides, e.g., glucan, galactan, mannan, and C5 polysaccharides,e.g., xylan and arabinan, in the fiber rich products in lines 217 and317, an ASTM test procedure can be used. More particularly, the testprocedure outlined in ASTM E1758-01 (2015) can be used to determine theamounts of any C6 polysaccharides and/or C5 polysaccharides in the fiberrich products in lines 217 and 317. In other examples, rather than usingthe NREL Chemical Analysis Standard Test Procedure, “Determination ofStarch in Solid Biomass Sample”, Version 2005 to determine the amount ofstarch in the fiber rich products in lines 217 and 317, an AOAC, AACC,and/or ICC test procedure can be used. More particularly, in otherexamples the test procedures outlined in AOAC Method 996.11, AACC Method76.13, and/or ICC Standard Method No. 168 can be used to determine theamount of starch in the fiber rich products in lines 217 and 317.Accordingly, it should be understood that the amount of C6polysaccharides, C5 polysaccharides, starch, and other components in thefiber rich products in lines 217 and 317 can be determined using anycombination of these standardized tests or any other standardized testcapable of determining the amount of any one or more of thecarbohydrates or starch in the fiber rich products in lines 217 and 317.

In some examples, the fiber rich products in lines 217 and 317 can havean ethanol potential of at least 90 gallons of ethanol per 1,000kilograms of the fiber rich product, at least 91 gallons of ethanol per1,000 kilograms of the fiber rich product, at least 92 gallons ofethanol per 1,000 kilograms of the fiber rich product, at least 93gallons of ethanol per 1,000 kilograms of the fiber rich product, atleast 94 gallons of ethanol per 1,000 kilograms of the fiber richproduct, at least 95 gallons of ethanol per 1,000 kilograms of the fiberrich product, at least 96 gallons of ethanol per 1,000 kilograms of thefiber rich product, at least 97 gallons of ethanol per 1,000 kilogramsof the fiber rich product, at least 98 gallons of ethanol per 1,000kilograms of the fiber rich product, at least 99 gallons of ethanol per1,000 kilograms of the fiber rich product, at least 100 gallons ofethanol per 1,000 kilograms of the fiber rich product, at least 101gallons of ethanol per 1,000 kilograms of the fiber rich product, atleast 102 gallons of ethanol per 1,000 kilograms of the fiber richproduct, at least 103 gallons of ethanol per 1,000 kilograms of thefiber rich product, at least 104 gallons of ethanol per 1,000 kilogramsof the fiber rich product, at least 105 gallons of ethanol per 1,000kilograms of the fiber rich product, at least 107, at least 110 gallonsof ethanol per 1,000 kilograms of the fiber rich product, at least 115gallons of ethanol per 1,000 kilograms of the fiber rich product, atleast 120 gallons of ethanol per 1,000 kilograms of the fiber richproduct, at least 125 gallons of ethanol per 1,000 kilograms of thefiber rich product, at least 130 gallons of ethanol per 1,000 kilogramsof the fiber rich product, at least 135 gallons of ethanol per 1,000kilograms of the fiber rich product, or at least 140 gallons of ethanolper 1,000 kilograms of the fiber rich product. For example, the fiberrich products in lines 217 and 317 can have an ethanol potential ofabout 92 gallons of ethanol per 1,000 kilograms of the fiber richproduct, about 96 gallons of ethanol per 1,000 kilograms of the fiberrich product, about 99 gallons of ethanol per 1,000 kilograms of thefiber rich product, about 103 gallons of ethanol per 1,000 kilograms ofthe fiber rich product, or about 105 gallons of ethanol per 1,000kilograms of the fiber rich product to about 130 gallons of ethanol per1,000 kilograms of the fiber rich product, about 135 gallons of ethanolper 1,000 kilograms of the fiber rich product, about 140 gallons ofethanol per 1,000 kilograms of the fiber rich product, about 145 gallonsof ethanol per 1,000 kilograms of the fiber rich product, about 150gallons of ethanol per 1,000 kilograms of the fiber rich product, orabout 155 gallons of ethanol per 1,000 kilograms of the fiber richproduct. In another example, the fiber rich products in lines 217 and317 can have an ethanol potential of about 90 gallons of ethanol per1,000 kilograms of the fiber rich product to about 160 gallons ofethanol per 1,000 kilograms of the fiber rich product, about 90 gallonsof ethanol per 1,000 kilograms of the fiber rich product to about 145gallons of ethanol per 1,000 kilograms of the fiber rich product, about100 gallons of ethanol per 1,000 kilograms of the fiber rich product toabout 110 gallons of ethanol per 1,000 kilograms of the fiber richproduct, or about 130 gallons of ethanol per 1,000 kilograms of thefiber rich product to about 145 gallons of ethanol per 1,000 kilogramsof the fiber rich product. The ethanol potential of the fiber richproduct, as discussed and described herein, is on a dry matter basis,i.e., based on a dried weight of the fiber rich product.

As used herein, the “ethanol potential” of the fiber rich product ismeasured in gallons of ethanol per 1,000 kilograms of the fiber richproduct and is determined according to the following procedure. Theextractives are removed from the fiber rich product as outlined in theNREL Chemical Analysis and Standard Test Procedure, “Determination ofExtractives in Bimass”, Version 2005. After the extractives are removed,water is removed from the fiber rich product as outlined in the NRELChemical Analysis and Standard Test Procedure, “Determination of TotalSolids in Biomass”, Version 2008. The amounts of any glucan, any xylan,any galactan, any arabinan, and any mannan in the fiber rich product,after removing the extractives and the water, are determined as outlinedin the NREL Chemical Analysis and Standard Test Procedure,“Determination of Structural Carbohydrates and Lignin in Biomass”,Version 2012. The amount of any starch in the fiber rich product, afterremoving the extractives and the water, is determined as outlined in theNREL Chemical Analysis Standard Test Procedure, “Determination of Starchin Solid Biomass Sample”, Version 2005.

The amounts (wt %) of any glucan, any galactan, any mannan, and anystarch are multiplied by 1,000 kg to determine the amount of any glucan,galactan, mannan, and starch in kilograms per 1,000 kg of the fiber richproduct (FRP). The mass (kg) of the glucan, galactan, mannan, and starchper 1,000 kg of the FRP are converted to mass (kg) monosaccharides per1,000 kg of the FRP by multiplying the mass of the glucan, galactan,mannan, and starch by 1.11 to account for the molecule of water thatadds to the polysaccharides when the sugar monomers are hydrolyzed fromthe polysaccharides. The mass (kg) of the monosaccharides per 1,000 kgof the FRP is multiplied by 0.51 (conversion of kilograms sugar tokilograms ethanol assuming 100% of theoretical yield). The kilograms ofethanol per 1,000 kg of the FRP is converted to liters (L) per 1,000 kgof the FRP by dividing the kilograms of ethanol by the density ofethanol (0.789 kg/L). The liters of ethanol per 1,000 kg of the FRP isconverted to gallons of ethanol per 1,000 kg of the FRP by dividing theliters of ethanol by 3.789.

The amounts (wt %) of any xylan and any arabinan are multiplied by 1,000kg to determine the amount of any xylan and any arabinan in kilogramsper 1,000 kg of the FRP. The mass (kg) of the xylan and arabinan per1,000 kg of the FRP are converted to mass (kg) of monosaccharides per1,000 kg of the FRP by multiplying the mass fraction by 1.136 to accountfor the molecule of water that adds to the polysaccharides when thesugar monomers are hydrolyzed from the polysaccharides. The mass (kg) ofmonosaccharides per 1,000 kg of the FRP is multiplied by 0.51(conversion of kilograms sugar to kilograms ethanol assuming 100% oftheoretical yield). The kilograms of ethanol per 1,000 kg of the FRP isconverted to liters (L) per 1,000 kg of the FRP by dividing thekilograms of ethanol by the density of ethanol (0.789 kg/L). The litersof ethanol per 1,000 kg of the FRP is converted to gallons of ethanolper 1,000 kg of the FRP by dividing the liters of ethanol by 3.789.

The theoretical amount of ethanol per 1,000 kilograms of the FRP, i.e.,the ethanol potential, that can potentially be produced from the glucan,galactan, mannan, and starch and the xylan and arabinan are added toprovide the ethanol potential of the fiber rich products. The ethanolpotential of the fiber rich products in lines 217 and 317 is limited toany glucan, any galactan, any mannan, any starch, any xylan, and anyarabinan present therein and does not include any additional C5polysaccharides and any additional C6 polysaccharides.

Returning to the saccharification mash in line 236 and thesaccharification mash that can be produced within the fermenter 342 viathe simultaneous saccharification and fermentation process, in someexamples, if the fiber rich product is contacted with an acid to producethe pretreated fiber rich product, the saccharification mash in line 236and/or the saccharification mash produced within the fermenter 342 canbe fermented in the fermenter 242 and 342, respectively, to produce atleast 25 gallons of ethanol per 1,000 kilograms of the saccharificationmash, at least 30 gallons of ethanol per 1,000 kilograms of thesaccharification mash, at least 35 gallons of ethanol per 1,000kilograms of the saccharification mash, at least 40 gallons of ethanolper 1,000 kilograms of the saccharification mash, at least 45 gallons ofethanol per 1,000 kilograms of the saccharification mash, at least 50gallons of ethanol per 1,000 kilograms of the saccharification mash, atleast 60 gallons of ethanol per 1,000 kilograms of the saccharificationmash, or at least 65 gallons of ethanol per 1,000 kilograms of thesaccharification mash. For example, if the fiber rich product iscontacted with an acid to produce the pretreated fiber rich product, thesaccharification mash in line 236 and/or the saccharification mashproduced within the fermenter 342 can be fermented in the fermenter 242and 342, respectively, to produce about 25 gallons of ethanol per 1,000kilograms of the saccharification mash, about 30 gallons of ethanol per1,000 kilograms of the saccharification mash, about 35 gallons ofethanol per 1,000 kilograms of the saccharification mash, about 40gallons of ethanol per 1,000 kilograms of the saccharification mash, orabout 45 gallons of ethanol per 1,000 kilograms of the saccharificationmash to about 50 gallons of ethanol per 1,000 kilograms of thesaccharification mash, about 55 gallons of ethanol per 1,000 kilogramsof the saccharification mash, about 60 gallons of ethanol per 1,000kilograms of the saccharification mash, or about 65 gallons of ethanolper 1,000 kilograms of the saccharification mash.

In some examples, if the fiber rich product is contacted with a base toproduce the pretreated fiber rich product, the saccharification mash inline 236 and/or the saccharification mash produced within the fermenter342 can be fermented in the fermenter 242 and 342, respectively, toproduce at least 25 gallons of ethanol per 1,000 kilograms of thesaccharification mash, at least 30 gallons of ethanol per 1,000kilograms of the saccharification mash, at least 35 gallons of ethanolper 1,000 kilograms of the saccharification mash, at least 40 gallons ofethanol per 1,000 kilograms of the saccharification mash, at least 45gallons of ethanol per 1,000 kilograms of the saccharification mash, atleast 50 gallons of ethanol per 1,000 kilograms of the saccharificationmash, at least 55 gallons of ethanol per 1,000 kilograms of thesaccharification mash, at least 60 gallons of ethanol per 1,000kilograms of the saccharification mash, or at least 65 gallons ofethanol per 1,000 kilograms of the saccharification mash. For example,if the fiber rich product is contacted with a base to produce thepretreated fiber rich product, the saccharification mash in line 236and/or the saccharification mash produced within the fermenter 342 canbe fermented in the fermenter 242 and 342, respectively, to produceabout 25 gallons of ethanol per 1,000 kilograms of the saccharificationmash, about 30 gallons of ethanol per 1,000 kilograms of thesaccharification mash, about 35 gallons of ethanol per 1,000 kilogramsof the saccharification mash, about 40 gallons of ethanol per 1,000kilograms of the saccharification mash, or about 45 gallons of ethanolper 1,000 kilograms of the saccharification mash to about 50 gallons ofethanol per 1,000 kilograms of the saccharification mash, about 55gallons of ethanol per 1,000 kilograms of the saccharification mash,about 60 gallons of ethanol per 1,000 kilograms of the saccharificationmash, or about 65 gallons of ethanol per 1,000 kilograms of thesaccharification mash. The amount of ethanol produced per 1,000kilograms of the saccharification mash, as discussed and describedherein, is on a dry matter basis, i.e., based on a dried weight of thesaccharification mash.

Returning to the stillage protein products in lines 256 and/or 356, thestillage protein products can include, but are not limited to, protein,fat, ash, neutral detergent fibers, acid detergent fibers, yeast, or anymixture thereof. In some examples, the stillage protein products inlines 256 and 356 can include about 40 wt %, about 45 wt %, or about 50wt % to about 60 wt %, about 70 wt %, or about 80 wt % of protein, basedon a dry weight of the stillage protein product. In some examples, eachstillage protein products in lines 256 and 356 can include about 2 wt %,about 5 wt %, or about 8 wt % of fat to about 12 wt %, about 17 wt %, orabout 20 wt % of the fat, based on the dry weight of the stillageprotein product. In some examples, the stillage protein products inlines 256 and 356 can include about 0.5 wt %, about 1 wt %, or about 2wt % to about 3 wt %, about 4 wt %, or about 5 wt % of ash, based on thedry weight of the stillage protein product. In some examples, thestillage protein products in lines 256 and 356 can include about 1 wt %,about 5 wt %, about 10 wt %, or about 15 wt % to about 20 wt %, about 25wt %, or about 30 wt % of the neutral detergent fibers, based on the dryweight of the stillage protein product. In some examples, the stillageprotein products in lines 256 and 356 can include about 1 wt %, about 2wt %, or about 5 wt % to about 8 wt %, about 10 wt %, or about 15 wt %of acid detergent fibers, based on the dry weight of the stillageprotein product. In some examples, the stillage protein products inlines 256 and 356 can include about 15 wt %, about 17 wt %, about 20 wt%, or about 23 wt % to about 25 wt %, about 27 wt %, about 30 wt %,about 33 wt %, or about 35 wt % of yeast, based on the dry weight of thestillage protein product. In other examples, the stillage proteinproducts in lines 256 and 356 can include at least 15 wt %, at least 16wt %, at least 17 wt %, at least 18 wt %, at least 19 wt %, at least 20wt %, at least 21 wt %, at least 22 wt %, at least 23 wt %, at least 24wt %, or at least 25 wt % to about 26 wt %, about 27 wt %, about 28 wt%, about 29 wt %, about 30 wt %, about 31 wt %, about 32 wt %, about 33wt %, about 34 wt %, or about 35 wt % of yeast, based on the dry weightof the stillage protein product. In some example, the stillage proteinproducts in lines 256 and 356 can also include water. For example, thestillage protein products in lines 256 and 356 can include about 4 wt %,about 5 wt %, about 6 wt %, or about 7 wt % to about 8 wt %, about 10 wt%, about 12 wt % of water, or about 15 wt % of water, based on a totalweight of the stillage protein product.

In some examples, the stillage protein products in lines 256 and 356 caninclude about 40 wt % to about 80 wt % of protein, about 3 wt % to about20 wt % of fat, about 1 wt % to about 4 wt % of ash, about 2 wt % toabout 30 wt % of neutral detergent fibers, about 1 wt % to about 15 wt %of acid detergent fibers, and about 15 wt % to about 35 wt % of yeast,based on dry weight of the stillage protein product. In some examples,the stillage protein products in lines 256 and 356 can include about 40wt % to about 80 wt % of protein, about 3 wt % to about 20 wt % of fat,about 1 wt % to about 4 wt % of ash, about 2 wt % to about 30 wt % ofneutral detergent fibers, about 2 wt % to about 12 wt % of aciddetergent fibers, and about 18 wt % to about 32 wt % of yeast, based ondry weight of the stillage protein product, and about 4 wt % to about 15wt % of water, based on a total weight of the stillage protein product.In some examples, the stillage protein products in lines 256 and 356 caninclude about 45 wt % to about 60 wt % of protein, about 2 wt % to about8 wt % of fat, about 1 wt % to about 4 wt % of ash, about 2 wt % toabout 12 wt % of neutral detergent fibers, about 5 wt % to about 8 wt %of acid detergent fibers, and about 20 wt % to about 30 wt % of yeast,based on dry weight of the stillage protein product. In some examples,the stillage protein products in lines 256 and 356 can include about 45wt % to about 60 wt % of protein, about 2 wt % to about 8 wt % of fat,about 1 wt % to about 4 wt % of ash, about 2 wt % to about 12 wt % ofneutral detergent fibers, about 1 wt % to about 15 wt % of aciddetergent fibers, and about 20 wt % to about 30 wt % of yeast, based ondry weight of the stillage protein product, and about 5 wt % to about 12wt % of water, based on a total weight of the stillage protein product.In other examples, the stillage protein products in lines 256 and 356can include about 50 wt % to about 54 wt % of protein, about 3 wt % toabout 6 wt % of fat, about 1 wt % to about 4 wt % of ash, about 4 wt %to about 10 wt % of neutral detergent fibers, about 3 wt % to about 12wt % of acid detergent fibers, and about 20 wt % to about 30 wt % ofyeast, based on dry weight of the stillage protein product. In otherexamples, the stillage protein products in lines 256 and 356 can includeabout 50 wt % to about 54 wt % of protein, about 3 wt % to about 6 wt %of fat, about 1 wt % to about 4 wt % of ash, about 4 wt % to about 10 wt% of neutral detergent fibers, about 5 wt % to about 15 wt % of aciddetergent fibers, and about 20 wt % to about 30 wt % of yeast, based ondry weight of the stillage protein product, and about 5 wt % to about 12wt % of water, based on a total weight of the stillage protein product.In other examples, the stillage protein products in lines 256 and 356can include about 50 wt % to about 54 wt % of protein, about 3 wt % toabout 5 wt % of fat, about 1 wt % to about 3 wt % of ash, about 6 wt %to about 7 wt % of neutral detergent fibers, about 5 wt % to about 8 wt% of acid detergent fibers, and about 20 wt % to about 30 wt % of yeast,based on dry weight of the stillage protein product. In other examples,the stillage protein products in lines 256 and 356 can include about 50wt % to about 54 wt % of protein, about 3 wt % to about 5 wt % of fat,about 1 wt % to about 3 wt % of ash, and about 6 wt % to about 7 wt % ofneutral detergent fibers, based on dry weight of the stillage proteinproduct, and about 6 wt % to about 10 wt % of water, based on a totalweight of the stillage protein product.

The protein in the stillage protein products can be determined accordingto the AOAC 990.03 (2000) test method. The fat in the stillage proteinproducts can be determined according to the AOAC 920.39 (2000) testmethod. Ash is the inorganic residue (minerals) remaining after anywater and organic matter have been removed by heating in a furnace. Theamount of ash in the stillage protein products can be determinedaccording to test method AOAC 945.02 (2000). The neutral detergent fiber(NDF) in the stillage protein products can be measured according to theNeutral Detergent Fiber in Feeds Filter Bag Technique (for A200 andA2001), as developed and defined by Ankom Technology, and referred to as(NDF Method, Method 13, last revised on Sep. 21, 2016). The NDF is theresidue remaining after digesting in a detergent solution. The fiberresidues are predominantly hemicellulose, cellulose, and lignin. Theacid detergent fiber (ADF) in the stillage protein products can bemeasured according to the Acid Detergent Fiber in Feeds Filter BagTechnique (for A200 and A2001), as developed and defined by AnkomTechnology, and referred to as (ADF Method, Method 12 last revised onSep. 21, 2016). The ADF is the residue remaining after digesting withsulfuric acid and detergent solution. The fiber residues arepredominantly cellulose and lignin. Any water or moisture in thestillage protein products can be determined according to test methodAOAC 934.01 (2000) test method.

Ground Corn Product

Returning to the ground corn product in line 103, the ground cornproduct can be quantified by having a particle size distribution, suchas by weight percent (wt %) and/or volume percent (vol %), for specifiedparticle sizes. The particle size and the particle size distribution ofthe ground corn product can be analyzed or otherwise determined byvarious particle size analyzers, such as laser diffraction analyzers,static and/or dynamic light scattering analyzers, zeta potentialanalyzers, sieve shaker with graduation test, and others. Generally, theparticle size distribution of the ground corn product by weight can bemeasured using sieves and the particle size distribution of the groundcorn product by volume can be measured by laser diffraction, as furtherdiscussed and described below.

The particle size and the particle size distribution of the ground cornproduct by weight can be measured or otherwise determined with a sieveshaker, such as the RO-TAP® RX-29 sieve shaker, commercially availablefrom W. S. Tyler Industrial Group. The sieves analysis can be performedaccording to the AOAC Official Method 965.22-1966, “Sorting CornGrits—Sieving Method,” available from AOAC International. Sieve sizes of850 μm, 425 μm, 250 μm, 180 μm, 150 μm, and 105 μm can be used tocategorize the particle size distribution of the ground corn product byweight.

The amount of the ground corn product that can have a particle size ofless than 100 μm can be about 10 wt %, about 15 wt %, about 20 wt %,about 25 wt %, about 30 wt %, about 35 wt %, or about 40 wt % to about45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt %,about 70 wt %, about 75 wt %, or greater, as measured according to AOAC965.22-1966. For example, about 10 wt % to about 68 wt %, about 32 wt %to about 68 wt %, about 41 wt % to about 66 wt %, about 32 wt % to about62 wt %, or about 35 wt % to about 58 wt % of the ground corn productcan have a particle size of less than 100 μm, as measured according toAOAC 965.22-1966. In some examples, greater than 10 wt %, greater than15 wt %, greater than 20 wt %, greater than 25 wt %, greater than 30 wt%, greater than 35 wt %, greater than 40 wt %, greater than 45 wt %,greater than 50 wt %, greater than 55 wt %, greater than 60 wt %,greater than 65 wt %, or greater than 70 wt % of the ground corn productcan have a particle size of less than 100 μm, as measured according toAOAC 965.22-1966. In other examples, greater than 10 wt %, greater than15 wt %, greater than 20 wt %, greater than 25 wt %, greater than 30 wt%, greater than 35 wt %, greater than 40 wt %, greater than 45 wt %, orgreater than 50 wt % to about 55 wt %, about 60 wt %, about 65 wt %, orabout 70 wt % of the ground corn product can have a particle size ofless than 100 μm, as measured according to AOAC 965.22-1966.

The amount of the ground corn product that can have a particle size of105 μm or less can be about 30 wt %, about 35 wt %, or about 40 wt % toabout 45 wt %, about 50 wt %, about 55 wt %, about 60 wt %, about 65 wt%, about 70 wt %, about 75 wt %, or greater, as measured according toAOAC 965.22-1966. For example, about 32 wt % to about 68 wt %, about 41wt % to about 66 wt %, about 32 wt % to about 62 wt %, or about 35 wt %to about 58 wt % of the ground corn product can have a particle size of105 μm or less, as measured according to AOAC 965.22-1966. In someexamples, greater than 30 wt %, greater than 35 wt %, greater than 40 wt%, greater than 45 wt %, greater than 50 wt %, greater than 55 wt %,greater than 60 wt %, greater than 65 wt %, or greater than 70 wt % ofthe ground corn product can have a particle size of 105 μm or less, asmeasured according to AOAC 965.22-1966. In other examples, greater than25 wt %, greater than 30 wt %, greater than 35 wt %, greater than 40 wt%, greater than 45 wt %, or greater than 50 wt % to about 55 wt %, about60 wt %, about 65 wt %, or about 70 wt % of the ground corn product canhave a particle size of greater than 105 μm, as measured according toAOAC 965.22-1966.

The amount of the ground corn product that can have a particle size of150 μm or less can be about 41 wt % to about 79 wt %, about 57 wt % toabout 90 wt %, about 57 wt % to about 78 wt %, or about 57 wt % to about75 wt %, as measured according to AOAC 965.22-1966. In some examples,greater than 40 wt %, greater than 50 wt %, greater than 60 wt %,greater than 70 wt %, greater than 75 wt %, or greater than 80 wt % ofthe ground corn product can have a particle size of 150 μm or less, asmeasured according to AOAC 965.22-1966.

The amount of the ground corn product that can have a particle size of180 μm or less can be about 52 wt % to about 97 wt %, about 58 wt % toabout 90 wt %, about 56 wt % to about 81 wt %, or about 62 wt % to about97 wt %, as measured according to AOAC 965.22-1966. In some examples,greater than 50 wt %, greater than 60 wt %, greater than 70 wt %,greater than 80 wt %, greater than 90 wt %, greater than 93 wt %,greater than 95 wt %, or greater than 97 wt % of the ground corn productcan have a particle size of 180 μm or less, as measured according toAOAC 965.22-1966.

The amount of the ground corn product that can have a particle size of250 μm or less can be about 71 wt % to about 98 wt %, about 81 wt % toabout 98 wt %, about 91 wt % to about 98 wt %, or about 71 wt % to about92 wt %, as measured according to AOAC 965.22-1966. In some examples,greater than 70 wt %, greater than 80 wt %, greater than 85 wt %,greater than 90 wt %, greater than 93 wt %, greater than 95 wt %,greater than 96 wt %, greater than 97 wt %, or greater than 98 wt % ofthe ground corn product can have a particle size of 250 μm or less, asmeasured according to AOAC 965.22-1966.

The amount of the ground corn product that can have a particle size of425 μm or less can be about 87 wt % to about 96 wt %, about 87 wt % toabout 95 wt %, about 87 wt % to about 99.9 wt %, or about 96 wt % toabout 99.9 wt %, as measured according to AOAC 965.22-1966. In someexamples, greater than 85 wt %, greater than 86 wt %, greater than 87 wt%, greater than 88 wt %, greater than 89 wt %, greater than 90 wt %,greater than 91 wt %, greater than 92 wt %, greater than 93 wt %,greater than 94 wt %, greater than 95 wt %, greater than 96 wt %,greater than 97 wt %, greater than 98 wt %, greater than 99 wt %,greater than 99.5 wt %, greater than 99.7 wt %, or greater than 99.9 wt% of the ground corn product can have a particle size of 425 μm or less,as measured according to AOAC 965.22-1966. In other examples, greaterthan 80 wt %, greater than 83 wt %, greater than 85 wt %, greater than87 wt %, greater than 90 wt %, greater than 93 wt %, or greater than 95wt % of the ground corn product can have a particle size of 425 μm orless, as measured according to AOAC 965.22-1966. In some examples 100%of the ground corn product can have a particle size of 425 μm or less.

The amount of the ground corn product that can have a particle size of850 μm or less can be about 98 wt % to about 99.95 wt %, about 99.2 wt %to about 99.9 wt %, about 99.2 wt % to about 99.95 wt %, or about 99.9wt % to about 99.95 wt %, as measured according to AOAC 965.22-1966. Insome examples, greater than 97 wt %, greater than 98 wt %, greater than99 wt %, greater than 99.3 wt %, greater than 99.5 wt %, greater than99.7 wt %, greater than 99.9 wt %, greater than 99.91 wt %, greater than99.93 wt %, or greater than 99.95 wt % of the ground corn product canhave a particle size of 850 μm or less, as measured according to AOAC965.22-1966.

In some examples, about 30 wt % to about 65 wt % of the ground cornproduct can have a particle size of 105 μm or less; about 40 wt % toabout 80 wt % of the ground corn product can have a particle size of 150μm or less; about 50 wt % to about 97 wt % of the ground corn productcan have a particle size of 180 μm or less; about 70 wt % to about 98 wt% of the ground corn product can have a particle size of 250 μm or less;about 85 wt % to about 99.9 wt % of the ground corn product can have aparticle size of 425 μm or less; and about 98 wt % to about 99.95 wt %of the ground corn product can have a particle size of 850 μm or less,as measured according to AOAC 965.22-1966. In other examples, greaterthan 30 wt %, greater than 40 wt %, greater than 50 wt %, or greaterthan 60 wt % of the ground corn product can have a particle size of 105μm or less; greater than 40 wt %, greater than 50 wt %, greater than 60wt %, or greater than 70 wt % of the ground corn product can have aparticle size of 150 μm or less; greater than 50 wt %, greater than 60wt %, greater than 70 wt %, or greater than 80 wt % of the ground cornproduct can have a particle size of 180 μm or less; greater than 70 wt%, greater than 80 wt %, greater than 90 wt %, or greater than 95 wt %of the ground corn product for a particle size of 250 μm or less;greater than 85 wt %, greater than 90 wt %, greater than 95 wt %,greater than 97 wt %, greater than 99 wt %, greater than 99.5 wt %, orgreater than 99.9 wt % of the ground corn product can have a particlesize of 425 μm or less; greater than 98 wt %, greater than 99 wt %,greater than 99.5 wt %, greater than 99.9 wt %, greater than 99.93 wt %,or greater than 99.95 wt % of the ground corn product can have aparticle size of 850 μm or less, as measured according to AOAC965.22-1966. In at least one example, greater than 25 wt %, greater than30 wt %, greater than 35 wt %, greater than 40 wt %, or greater than 45wt % of the ground corn product can have a particle size of greater than105 μm, and greater than 80 wt %, greater than 85 wt %, greater than 90wt %, or greater than 95 wt % of the ground corn product can have aparticle size of 425 μm or less, as measured according to AOAC965.22-1966.

The particle size and the particle size distribution of the ground cornproduct by volume can be analyzed on a LS™ 13-320 laser diffractionparticle size analyzer with a Tornado dry sample module attachment, bothcommercially available from Beckman Coulter Life Sciences. The laserdiffraction particle analysis can be conducted according to the ISO13320:2009, “Particle Size Analysis Laser Diffraction Methods,”available from International Organization for Standardization.

The amount of the ground corn product that can have a particle size of25 μm or less can be about 2 vol % to about 10 vol %, about 2 vol % toabout 9 vol %, about 2 vol % to about 8 vol %, or about 3 vol % to about10 vol %, as measured according to ISO 13320:2009. In some examples,greater than 2 vol %, greater than 4 vol %, greater than 6 vol %,greater than 8 vol %, or greater than 9 vol % of the ground corn productcan have a particle size of 25 μm or less, as measured according to ISO13320:2009.

The amount of the ground corn product that can have a particle size of60 μm or less can be about 16 vol % to about 24 vol %, about 19 vol % toabout 25 vol %, about 16 vol % to about 26 vol %, or about 19 vol % toabout 28 vol %, as measured according to ISO 13320:2009. In someexamples, greater than 10 vol %, greater than 13 vol %, greater than 15vol %, greater than 17 vol %, greater than 18 vol %, greater than 20 vol%, greater than 22 vol %, greater than 23 vol %, greater than 25 vol %,greater than 28 vol %, greater than t 30 vol %, greater than 35 vol % ofthe ground corn product can have a particle size of 60 μm or less, asmeasured according to ISO 13320:2009.

The amount of the ground corn product that can have a particle size of400 μm or less can be about 42 vol % to about 74 vol %, about 42 vol %to about 71 vol %, about 59 vol % to about 71 vol %, or about 54 vol %to about 71 vol % of the ground corn product can have a particle size of400 μm or less, as measured according to ISO 13320:2009. In someexamples, greater than 40 vol %, greater than 45 vol %, greater than 50vol %, greater than 55 vol %, greater than 60 vol %, greater than 65 vol%, or greater than 70 vol % of the ground corn product can have aparticle size of 400 μm or less, as measured according to ISO13320:2009.

The amount of the ground corn product that can have a particle size of800 μm or less can be about 86 vol % to about 90 vol %, about 86 vol %to about 96 vol %, about 87 vol % to about 95 vol %, or about 87 vol %to about 96 vol %, as measured according to ISO 13320:2009. In someexamples, greater than 85 vol %, greater than 87 vol %, greater than 89vol %, greater than 90 vol %, greater than 93 vol %, greater than 94 vol%, or greater than 95 vol % of the ground corn product can have aparticle size of 800 μm or less, as measured according to ISO13320:2009.

In one or more examples, about 10 vol % to about 30 vol % of the groundcorn product can have a particle size of 60 μm or less; about 40 vol %to about 70 vol % of the ground corn product can have a particle size of400 μm or less; and about 85 vol % to about 95 vol % of the ground cornproduct can have a particle size of 800 μm or less. In other examples,greater than 10 vol %, greater than 15 vol %, greater than 18 vol %,greater than 20 vol %, greater than 25 vol %, greater than 28 vol %, orgreater than 30 vol % of the ground corn product can have a particlesize of 60 μm or less; greater than 40 vol %, greater than 50 vol %,greater than 55 vol %, greater than 60 vol %, or greater than 70 vol %of the ground corn product can have a particle size of 400 μm or less;and greater than 85 vol %, greater than 90 vol %, or greater than 95 vol% of the ground corn product can have a particle size of 800 μm or less.For example, greater than 18 vol % of the ground corn product can have aparticle size of 60 μm or less and greater than 50 vol % of the groundcorn product can have a particle size of 400 μm or less, as measuredaccording to ISO 13320:2009.

In some examples, greater than 20 vol % of the ground corn product canhave a particle size of 60 μm or less and greater than 60 vol % of theground corn product can have a particle size of 400 μm or less, asmeasured according to ISO 13320:2009. In other examples, greater than 18vol % of the ground corn product can have a particle size of 60 μm orless and greater than 85 vol % of the ground corn product can have aparticle size of 800 μm or less, as measured according to ISO13320:2009. In some examples, greater than 50 vol % of the ground cornproduct can have a particle size of 400 μm or less and greater than 85vol % of the ground corn product can have a particle size of 800 μm orless, as measured according to ISO 13320:2009. In other examples,greater than 22 vol % of the ground corn product can have a particlesize of 60 μm or less, greater than 60 vol % of the ground corn producthaving a particle size of 400 μm or less, and greater than 90 vol % ofthe ground corn product can have a particle size of 800 μm or less, asmeasured according to ISO 13320:2009.

The volumetric particle size distribution of the ground corn product canbe provided by particle size, d_(v), where v is the volume percent ofthe ground corn product that has a particle size smaller than thespecified value. For example, if the ground corn product has a d₁₀ byvolume percent of 18 μm, then 10 vol % of the ground corn product has aparticle size of less than 18 μm and 90 vol % of the ground corn producthas a particle size of 18 μm and larger. In another example, if theground corn product has a d₅₀ by volume percent of 170 μm, then 50 vol %of the ground corn product has a particle size of less than 170 μm and50 vol % of the ground corn product has a particle size of 170 μm andlarger. In another example, if the ground corn product has a d₉₀ byvolume percent of 800 μm, then 90 vol % of the ground corn product has aparticle size of less than 800 μm and 10 vol % of the ground cornproduct has a particle size of 800 μm and larger.

The ground corn product can have a d₁₀ by volume percent of 5 μm, 10 μm,12 μm, or 15 μm to 20 μm, 25 μm, 30 μm, 40 μm, or 50 μm, as measuredaccording to ISO 13320:2009. For example, the ground corn product canhave a d₁₀ by volume percent of 10 μm to 30 μm, 10 μm to 25 μm, 10 μm to20 μm, 12 μm to 30 μm, 12 μm to 25 μm, 12 μm to 20 μm, 14 μm to 30 μm,14 μm to 25 μm, 14 μm to 20 μm, 15 μm to 25 μm, 16 μm to 30 μm, or 16 μmto 25 μm, as measured according to ISO 13320:2009.

The ground corn product can have a d₂₅ by volume percent of 30 μm, 40μm, or 50 μm to 55 μm, 60 μm, 70 μm, 80 μm, 90 μm, 100 μm, 110 μm, 120μm, 130 μm, 140 μm, or 150 μm, as measured according to ISO 13320:2009.For example, the ground corn product can have a d₂₅ by volume percent of30 μm to 120 μm, 30 μm to 110 μm, 30 μm to 101 μm, 30 μm to 93 μm, 30 μmto 88 μm, 30 μm to 75 μm, 30 μm to 66 μm, 30 μm to 55 μm, 40 μm to 120μm, 40 μm to 101 μm, 40 μm to 93 μm, 40 μm to 88 μm, 40 μm to 75 μm, 40μm to 66 μm, 40 μm to 55 μm, 40 μm to 48 μm, 50 μm to 120 μm, 50 μm to110 μm, 50 μm to 101 μm, 50 μm to 97 μm, 50 μm to 93 μm, 50 μm to 75 μm,or 50 μm to 66 μm, as measured according to ISO 13320:2009.

The ground corn product can have a d₅₀ by volume percent of 100 μm, 110μm, 125 μm, or 150 μm to 200 μm, 250 μm, 300 μm, 350 μm, 400 μm, 450 μm,or 500 μm, as measured according to ISO 13320:2009. For example, theground corn product can have a d₅₀ by volume percent of 100 μm to 500μm, 100 μm to 450 μm, 100 μm to 400 μm, 100 μm to 350 μm, 100 μm to 300μm, 100 μm to 250 μm, 100 μm to 200 μm, 100 μm to 150 μm, 110 μm to 500μm, 110 μm to 400 μm, 110 μm to 300 μm, 110 μm to 250 μm, 110 μm to 200μm, 110 μm to 150 μm, 150 μm to 500 μm, 150 μm to 450 μm, 150 μm to 400μm, 150 μm to 350 μm, 150 μm to 300 μm, 150 μm to 250 μm, 150 μm to 200μm, or 150 μm to 175 μm, as measured according to ISO 13320:2009.

The ground corn product can have a d₇₅ by volume percent of 350 μm, 375μm, 400 μm, or 425 μm to 450 μm, 500 μm, 550 μm, 600 μm, 650 μm, or 700μm, as measured according to ISO 13320:2009. For example, the groundcorn product can have a d₇₅ by volume percent of 350 μm to 700 μm, 350μm to 650 μm, 350 μm to 600 μm, 350 μm to 550 μm, 350 μm to 500 μm, 350μm to 450 μm, 350 μm to 400 μm, 375 μm to 700 μm, 375 μm to 600 μm, 375μm to 500 μm, 375 μm to 450 μm, 375 μm to 400 μm, 400 μm to 700 μm, 400μm to 600 μm, 400 μm to 500 μm, 425 μm to 700 μm, 425 μm to 650 μm, 425μm to 600 μm, 425 μm to 550 μm, or 425 μm to 500 μm, as measuredaccording to ISO 13320:2009.

The ground corn product can have a d₉₀ by volume percent of 650 μm, 700μm, 750 μm, or 800 μm to 850 μm, 900 μm, 950 μm, 1,000 μm, 1,050 μm, or1,100 μm, as measured according to ISO 13320:2009. For example, theground corn product can have a d₉₀ by volume percent of 650 μm to 1,100μm, 675 μm to 1,100 μm, 700 μm to 1,100 μm, 725 μm to 1,100 μm, 750 μmto 1,100 μm, 800 μm to 1,100 μm, 850 μm to 1,100 μm, 650 μm to 1,000 μm,675 μm to 1,000 μm, 700 μm to 1,000 μm, 725 μm to 1,000 μm, 750 μm to1,000 μm, 800 μm to 1,000 μm, 850 μm to 1,000 μm, 650 μm to 950 μm, 700μm to 950 μm, 725 μm to 950 μm, 750 μm to 950 μm, 800 μm to 950 μm, 850μm to 950 μm, 650 μm to 900 μm, 675 μm to 900 μm, 700 μm to 900 μm, 750μm to 900 μm, 800 μm to 900 μm, 650 μm to 850 μm, 675 μm to 850 μm, 700μm to 850 μm, or 750 μm to 850 μm, as measured according to ISO13320:2009.

The ground corn product can include, but is not limited to, pericarpparticles, floury endosperm particles, germ particles, starch particles,and fiber particles. The starch portions and the germ portions of thecorn kernels can be size-reduced to smaller sizes than the fibrousportions of the corn kernels. It is believed that this difference insizes of the corn portions is a result of the shearing action of themilling device (e.g., air swept pulverizer or disk mill fiberizer). Theground corn product, therefore, can include fiber particles withdifferent particle size distributions than the total particles of theground corn product.

In one or more examples, the fiber particles of the ground corn productcan have a d₅₀ by volume percent of 125 μm, 150 μm, or 250 μm to 300 μm,350 μm, 400 μm, or 500 μm and the total particles of the ground cornproduct can have a d₅₀ by volume percent of 100 μm, 125 μm, or 150 μm to200 μm, 300 μm, 400 μm, or 500 μm, as measured according to ISO13320:2009. For example, the fiber particles of the ground corn productcan have a d₅₀ by volume percent of 125 μm to 450 μm, 150 μm to 450 μm,or 175 μm to 400 μm and the total particles of the ground corn productcan have a d₅₀ by volume percent of 100 μm to 400 μm, 100 μm to 350 μm,or 125 μm to 300 μm, as measured according to ISO 13320:2009.

In one or more examples, a plurality of total particles of the groundcorn product can include a plurality of fiber particles. The fiberparticles in the ground corn product can have a d₅₀ by volume percent ofgreater than 160 μm, greater than 180 μm, greater than 200 μm, greaterthan 250 μm, greater than 300 μm, or greater than 350 μm to 500 μm andthe total particles of the ground corn product can have a d₅₀ by volumepercent of 100 μm to less than 300 μm, less than 350 μm, less than 450μm, or less than 500 μm, as measured according to ISO 13320:2009. Forexample, the fiber particles of the ground corn product can have a d₅₀by volume percent of greater than 200 μm and the total particles of theground corn product can have a d₅₀ by volume percent of less than 500μm, as measured according to ISO 13320:2009. In another example, thefiber particles of the ground corn product can have a d₅₀ by volumepercent of greater than 250 μm and the total particles of the groundcorn product can have a d₅₀ by volume percent of less than 450 μm, asmeasured according to ISO 13320:2009. In some examples, the fiberparticles of the ground corn product can have a d₅₀ by volume percent ofgreater than 300 μm and the total particles of the ground corn productcan have a d₅₀ by volume percent of less than 400 μm, as measuredaccording to ISO 13320:2009. In other examples, the fiber particles ofthe ground corn product can have a d₅₀ by volume percent of greater than350 μm and the total particles of the ground corn product can have a d₅₀by volume percent of less than 350 μm, as measured according to ISO13320:2009. In other examples, the fiber particles of the ground cornproduct can have a d₅₀ by volume percent of greater than 200 μm to 500μm and the total particles of the ground corn product can have a d₅₀ byvolume percent of 100 μm to less than 500 μm, as measured according toISO 13320:2009.

In other examples, the fiber particles of the ground corn product canhave a d₇₅ by volume percent of 375 μm, 400 μm, or 450 μm to 500 μm, 600μm, or 700 μm and the total particles of the ground corn product canhave a d₇₅ by volume percent of 350 μm, 400 μm, or 425 μm to 450 μm, 500μm, 600 μm, or 700 μm, as measured according to ISO 13320:2009. Forexample, the fiber particles of the ground corn product can have a d₇₅by volume percent of 375 μm to 700 μm, 400 μm to 600 μm, or 450 μm to700 μm and the total particles of the ground corn product can have a d₇₅by volume percent of 350 μm to 600 μm, 350 μm to 500 μm, or 325 μm to550 μm, as measured according to ISO 13320:2009.

It should be understood that the ground corn product or any portionthereof (e.g., fiber particles) can have a combination of any two ormore properties discussed and described above or elsewhere herein. Forexample, the ground corn product can have a combination of any two, anythree, any four, or more, of the following properties: the particle sizeby weight, the particle size by volume, the particle size distributionby weight, the particle size distribution by volume, the d₁₀ value, thed₂₅ value, the d₅₀ value, the d₇₅ value, the d₉₀ value, and thecrystallinity, which are discussed and described above or elsewhereherein.

The ground corn product and the corn pieces (e.g., corn kernels) fromwhich the ground corn product is ground can have the same composition orsubstantially the same composition. The corn pieces and the ground cornproduct can contain, but are not limited to, water, one or more starches(e.g., saccharides and oligosaccharides), one or more proteins,cellulose, one or more oils and/or greases (e.g., saturated andunsaturated fatty acids), one or more volatile organic compounds, othercomponents, or any combination thereof. Generally, for example, the cornpieces and the ground corn product can each include about 5 wt % toabout 40 wt % of water, about 15 wt % to about 25 wt % ofoligosaccharides, and about 0.5 wt % to about 5 wt % of corn oil.

The corn oil can be or include one or more oils and/or one or moregreases which can include one or more saturated fatty acids and/or oneor more unsaturated fatty acids. Illustrative saturated fatty acids andunsaturated fatty acids that can be contained in the corn pieces and theground corn product can be or include caprylic acid, capric acid,myristic acid, palmitic acid, stearic acid, arachidic acid, oleic acid,linoleic acid, linolenic acid, isomers thereof, or any mixture thereof.For example, the corn oil can include about 10 wt % to about 15 wt % ofpalmitic acid, about 1 wt % to about 2 wt % of stearic acid, about 0.5wt % to about 2 wt % of arachidic acid, about 20 wt % to about 40 wt %of oleic acid, about 45 wt % to about 65 wt % of linoleic acid, andabout 0.5 wt % to about 2 wt % of linolenic acid.

The corn pieces and the ground corn product can include about 0.5 wt %,about 0.8 wt %, about 1 wt %, about 1.5 wt %, or about 1.8 wt % to about2 wt %, about 2.2 wt %, about 2.5 wt %, about 2.7 wt %, about 3 wt %,about 3.2 wt %, about 3.5 wt %, about 3.7 wt %, about 4 wt %, about 4.5wt %, or more of corn oil, based on a solids weight of the corn piecesor the ground corn product. For example, the corn pieces and the groundcorn product can include about 0.5 wt % to about 4.5 wt %, about 0.5 wt% to about 4 wt %, about 0.5 wt % to about 3.5 wt %, about 0.5 wt % toabout 3 wt %, about 0.5 wt % to about 2.5 wt %, about 0.5 wt % to about2 wt %, about 0.5 wt % to about 1.5 wt %, about 0.5 wt % to about 1 wt%, about 1 wt % to about 4.5 wt %, about 1 wt % to about 4 wt %, about 1wt % to about 3.5 wt %, about 1 wt % to about 3 wt %, about 1 wt % toabout 2.5 wt %, about 1 wt % to about 2 wt %, about 1 wt % to about 1.5wt %, about 1 wt % to about 1.3 wt %, about 2 wt % to about 4.5 wt %,about 2 wt % to about 4 wt %, about 2 wt % to about 3.5 wt %, about 2 wt% to about 3 wt %, about 2 wt % to about 2.5 wt %, about 2 wt % to about2.3 wt %, about 2.5 wt % to about 4.5 wt %, about 2.5 wt % to about 4 wt%, about 2.5 wt % to about 3.5 wt %, about 2.5 wt % to about 3 wt %,about 2.5 wt % to about 2.8 wt %, about 3 wt % to about 4.5 wt %, about3 wt % to about 4 wt %, about 3 wt % to about 3.7 wt %, about 3 wt % toabout 3.5 wt %, or about 3 wt % to about 3.2 wt % of corn oil, based ona solids weight of the corn pieces or the ground corn product.

In one or more examples, the corn pieces and the ground corn product caninclude about 5 wt % to about 40 wt % of water, about 15 wt % to about25 wt % of soluble starches, about 5 wt % to about 15 wt % of cellulose,and about 0.5 wt % to about 4 wt % of corn oil, based on a solids weightof the corn pieces or the ground corn product. In some examples, thecorn pieces and the ground corn product can include about 10 wt % toabout 35 wt % of water, about 17 wt % to about 28 wt % of solublestarches, about 10 wt % to about 15 wt % of cellulose, and about 2 wt %to about 4 wt % of corn oil, based on a solids weight of the corn piecesor the ground corn product.

Corn pieces (e.g., corn kernels) can be milled, ground, pulverized,fiberized, or otherwise size-reduced to produce the ground corn product.The corn pieces can also be milled, ground, pulverized, fiberized, orotherwise size-reduced two, three, or more times to produce the groundcorn product. The plurality of corn pieces, therefore, can be or includesize-reduced corn that is further size-reduced to produce the groundcorn product. Illustrative corn pieces that are suitable to besize-reduced can be or include, but are not limited to, whole cornkernels, milled corn kernels, pulverized corn kernels, fiberized cornkernels, ground corn kernels, fragmented corn kernels, crushed cornkernels, smashed corn kernels, shredded corn kernels, other size-reducedcorn kernels, fresh corn kernels, dried corn kernels, or any mixturethereof.

In some examples, the corn pieces (e.g., corn kernels) can besize-reduced one or more times with a hammer mill, a roller mill, orother type of mill to produce the plurality of corn pieces that can befurther size-reduced one or more times with a high shear mill to producethe ground corn product. For example, the corn pieces can be passedthrough one or more hammer mills to produce size-reduced corn thatsubsequently can be passed through a disk mill fiberizer, an air sweptpulverizer, and/or any other high shear mills to produce the ground cornproduct. The ground corn product can be or include fiberized corn,pulverized corn, disk milled corn, other high shear milled corn, or anymixtures thereof.

The corn pieces can be introduced to a high shear mill that can have tworotating surfaces, such as a first rotatable disk and a second rotatabledisk. In other examples, the corn pieces can be introduced to a highshear mill that can have one rotating surface and one stationarysurface, such as one rotatable disk and one stationary disk, plate, orother surface. The corn pieces can make contact to the two rotatingsurfaces or can make contact to the one rotating surface and the onestationary surface to mill, shear, grind, fiberize, pulverize, orotherwise size-reduce the corn pieces between the two rotating surfacesor between the one rotating surface and the one stationary surface toproduce the ground corn product. For example, the high shear mill can bea disk attrition mill and the corn pieces can be milled or otherwiseside-reduced between: a rotatable disk and a stationary disk; arotatable disk and a stationary surface; or two rotatable disks toproduce the ground corn product. In some examples, the corn pieces canbe fiberized between two sets of triangular teeth, relatively sharpteeth, or fiberizing teeth of the disk attrition mill to producefiberized corn product. In other examples, the corn pieces can bepulverized between two sets of rectangular teeth, relatively dull teeth,or pulverizing teeth of the disk attrition mill to produce pulverizedcorn product. In some examples, at least one disk can have grindingteeth for fiberizing the corn pieces into the ground corn product.Various disk attrition mills can be used to fiberize and/or pulverize.Some disk attrition mills can have a fiberizing side and a pulverizingside which are independent from each other. Disk attrition mills thatcan be used to mill, grind, or otherwise size-reduce corn can include,for example, the 167.64 cm (66 inch) fiberizer, commercially availablefrom Reynolds Engineering and Equipment, Inc.

In one or more examples, the corn pieces can be introduced into a diskattrition mill, such as a high shear fiberizer or a high shearpulverizer. The disk attrition mill can include a first rotatable diskand either a second rotatable disk or a stationary surface. The diskattrition mill can have at least one set of grinding teeth disposed oneach of the first rotatable disk, the second rotatable disk, and thestationary surface. In some configurations, any of the first rotatabledisk, the second rotatable disk, or the stationary surface can be freeof grinding teeth. In some examples of the disk attrition mill, thefirst rotatable disk can have a first set of grinding teeth and eitherthe second rotatable disk or the stationary surface is free of grindingteeth. In other examples of the disk attrition mill, the first rotatabledisk can have a first set of grinding teeth and either the secondrotatable disk or the stationary surface can have a second set ofgrinding teeth.

The first rotatable disk and either the second rotatable disk or thestationary surface can be separated by a predetermined distance fromeach other to provide a shearing gap therebetween. The predetermineddistance can be fixed or adjustable. If the first rotatable disk and/oreither the second rotatable disk or the stationary surface have one ormore sets of grinding teeth, then the shearing gap can be measured bythe distance between two sets of grinding teeth or between one set ofgrinding teeth and either the rotatable disk or the stationary surface.For example, the shearing gap can be measured by the distance betweenthe first set of grinding teeth on the first rotatable disk and thesecond set of grinding teeth on either the second rotatable disk or thestationary surface. In another example, the shearing gap can be measuredby the distance between the first set of grinding teeth on the firstrotatable disk and either the second rotatable disk or the stationarysurface absent of grinding teeth. The shearing gap can be adjustedand/or can be maintained before and/or during the milling of the cornpieces to produce the ground corn product. The shearing gap can beadjusted to produce the ground corn product having the particle size ofthe ground corn product and a desired distribution of the particle sizeof the ground corn product. Once the ground corn product is producedwithin the shearing gap, the ground corm product can pass through theshearing gap to exit the disk mill.

The shearing gap or the distance between the first rotatable disk and/oreither the second rotatable disk or the stationary surface can be lessthan 3,000 μm, less than 2,600 μm, less than 2,000 μm, less than 1,500μm, less than 1,000 μm, less than 800 μm, less than 500 μm, or less than250 μm. The shearing gap or the distance between the first rotatabledisk and/or either the second rotatable disk or the stationary surfacecan be about 50 μm, about 100 μm, about 150 μm, or about 250 μm to about300 μm, about 500 μm, about 700 μm, about 800 μm, about 1,000 μm, about1,500 μm, about 2,000 μm, about 2,500 μm, or about 2,750 μm. Forexample, the shearing gap or the distance between the first rotatabledisk and/or either the second rotatable disk or the stationary surfacecan be about 250 μm to about 3,000 μm, about 400 μm to about 2,000 μm,about 500 μm to about 1,000 μm, about 700 μm to about 800 μm, about 700μm to about 2,800 μm, or about 600 μm to about 2,600 μm.

The corn pieces can be ground, milled, fiberized, pulverized, orotherwise size-reduced to produce the ground corn product that maintainsat least a substantial amount of the crystallinity relative to the cornpieces ground to produce the ground corn product. The ground cornproduct can have a crystallinity that is greater than 75%, about 80%,about 85%, or about 90% to about 92%, about 94%, about 95%, about 96%,about 97%, about 98%, about 99%, about 99.2%, about 99.5%, about 99.7%,about 99.8%, about 99.9%, about 99.95%, about 99.97%, about 99.98%,about 99.99%, or 100%, as compared to the crystallinity of the cornpieces ground to produce the ground corn product. For example, theground corn product can have a crystallinity that is greater than 75%,greater than 80%, greater than 85%, greater than 90%, greater than 92%,greater than 94%, greater than 95%, greater than 96%, greater than 97%,greater than 98%, greater than 99%, greater than 99.2%, greater than99.5%, greater than 99.7%, greater than 99.8%, greater than 99.9%,greater than 99.95%, greater than 99.97%, greater than 99.98%, greaterthan 99.99%, or 100%, as compared to the crystallinity of the cornpieces ground to produce the ground corn product.

For example, the ground corn product can have a crystallinity that isabout 80% to 100%, about 85% to 100%, about 90% to 100%, about 95% to100%, about 97% to 100%, about 98% to 100%, about 99% to 100%, about99.5% to 100%, about 99.9% to 100%, about 99.95% to 100%, about 75% toabout 99%, about 80% to about 99%, about 85% to about 99%, about 90% toabout 99%, about 95% to about 99%, about 97% to about 99%, about 98% toabout 99%, or about 98.5% to about 99%, as compared to the crystallinityof the corn pieces ground to produce the ground corn product. In otherexamples, the ground corn product can have a crystallinity that isgreater than 75% to 100%, greater than 80% to 100%, greater than 85% to100%, greater than 90% to 100%, greater than 95% to 100%, greater than97% to 100%, greater than 98% to 100%, greater than 99% to 100%, greaterthan 99.5% to 100%, greater than 99.9% to 100%, greater than 99.95% to100%, greater than 75% to about 99%, greater than 80% to about 99%,greater than 85% to about 99%, greater than 90% to about 99%, greaterthan 95% to about 99%, greater than 97% to about 99%, greater than 98%to about 99%, or greater than 98.5% to about 99%, as compared to thecrystallinity of the corn pieces ground to produce the ground cornproduct.

The ground corn product can have a crystallinity that is reduced by lessthan 25%, less than 23%, less than 20%, less than 17%, less than 15%,less than 12%, less than 10%, less than 8%, less than 6%, less than 5%,less than 4%, less than 3%, less than 2%, less than 1%, less than 0.8%,less than 0.5%, less than 0.3%, less than 0.2%, less than 0.1%, lessthan 0.05%, less than 0.03%, or less than 0.01%, as compared to thecrystallinity of the corn pieces ground to produce the ground cornproduct. For example, the ground corn product can have a crystallinitythat is reduced by less than 25% to about 0.001%, less than 25% to about0.01%, less than 25% to about 0.05%, less than 25% to about 0.1%, lessthan 10% to about 0.001%, less than 10% to about 0.01%, less than 10% toabout 0.05%, less than 10% to about 0.1%, less than 5% to about 0.001%,less than 5% to about 0.01%, less than 5% to about 0.05%, less than 5%to about 0.1%, less than 1% to about 0.001%, less than 1% to about0.01%, less than 1% to about 0.05%, less than 1% to about 0.1%, lessthan 0.1% to about 0.001%, less than 0.1% to about 0.01%, less than 0.1%to about 0.08%, or less than 0.1% to about 0.04%, as compared to thecrystallinity of the corn pieces ground to produce the ground cornproduct.

As used herein, the term “crystallinity” refers to a volume ratio of thecrystalline portion of cellulose to the total volume of cellulose thatincludes both the amorphous portion and the crystalline portion. Thedegree of crystallinity of the ground corn product can be calculatedfrom X-ray diffraction (XRD) data by using a crystalline areaintegration method based on Cheetham and Leping (Carbohydrate Polymers36:277-284 (1998)); Nara et al. (Starch 35,12:407-410 (1983)); andBenedetti et al. (Journal of Material Science 18.4:1039-1048 (1983)).The intensities are first normalized over a limited range of data (e.g.,10° to 30° 2-theta). The normalization is determined by a baselineconnecting the upper and lower bounds of 10° and 30° 2-theta and thendividing the intensities by the integrated area below the intensitiescurve and above the baseline. After normalization, a Savitzky-Golayfilter is used to smooth the data. The crystalline and amorphous regionscan be separated by a function that connects peak baselines. Thecrystalline portion is the upper region and the amorphous portion is thelower region. The crystalline portion area and the total diffractionarea are integrated. The degree of crystallinity is defined as the ratioof the crystalline area over the total diffraction area.

In one or more examples, at least a portion of the corn oil can beextracted or otherwise removed from the ground corn product, the slurrytank mixture containing the ground corn product, the liquefaction mashderived from the ground corn product, the fermentation mash, and/or thestillage. In some examples, the portion of the corn oil that isextracted from the ground corn product is the oil liberated from thecorn cellular matrix within the ground corn product and any other oilthat is bound by the corn cellular matrix remains in the ground cornproduct. The corn oil extraction and the corn oil testing can beperformed on the SPE-DEX® 3000XL Automated Extractor System and theSPEED-VAP™ Solvent Evaporation System, both commercially available fromthe Horizon Technology Company, using EPA Method 1664A. The corn oilremoved from the ground corn product can be greater than 0.6 wt %,greater than 0.7 wt %, or greater than 0.75 wt % to about 0.9 wt %,about 1 wt %, about 1.2 wt %, or greater of the total weight of theground corn product. For example, the corn oil removed from the groundcorn product can be greater than 0.6 wt % to about 1.2 wt %, greaterthan 0.65 wt % to about 1.1 wt %, or greater than 0.7 wt % to about 1.05wt % of the total weight of the ground corn product. In another example,the corn oil removed from the ground corn product, e.g., the stillage,can be greater than 0.6 wt %, greater than 0.7 wt %, greater than 0.75wt %, greater than 0.8 wt %, or greater than 0.85 wt % to about 0.9 wt%, about 1 wt %, about 1.2 wt %, about 1.3 wt %, about 1.4 wt %, about1.5 wt %, about 1.6 wt %, about 1.7 wt %, about 1.8 wt %, about 1.9 wt%, about 2 wt %, about 2.3 wt %, about 2.5 wt %, about 2.7 wt %, about 3wt %, about 3.3 wt %, about 3.5 wt %, about 3.7 wt %, about 4 wt %, orgreater of the total weight of the ground corn product.

EXAMPLES

In order to provide a better understanding of the foregoing discussion,the following non-limiting examples are offered. Although the examplescan be directed to specific embodiments, they are not to be viewed aslimiting the invention in any specific respect.

Corn Sample Grind Description

For Examples 1-4, the following mill or mills were used as specified ineach example. The hammer mill was a Model MG mill, manufactured by KellyDuplex Mill and Manufacturing Company in Springfield, Ohio. Thepulverizer was a Model 16-H air swept pulverizer manufactured bySchutz-O'Neill Company in Minneapolis, Minn. The disk mill fiberizer wasa Model TOQ-18 fiberizer, manufactured by Reynolds Engineering &Equipment, Inc. in Muscatine, Iowa.

Ex. 1 was corn that was passed through the hammer mill and through theair swept pulverizer. Raw whole corn kernels were milled to producehammermilled corn pieces. The hammer mill was operated at about 90 Hzwith a tip speed of about 124 meters per second (about 24,500 fpm) usinga number 8 screen (3.175 mm) or ( 8/64″, or 0.125″) at a feed rate ofabout 925 kg/hr (about 2,040 lbs/hr). The hammermilled corn pieces werepulverized in the air swept pulverizer to produce the ground cornproduct. The air swept pulverizer was operated at about 80 Hz with a tipspeed of about 157 meters per second (about 30,840 fpm) using three43.18 cm (about 17-inch) diameter CCD beater plates and a CLP liner at afeed rate of about 599 kg/hr (about 1,320 lbs/hr).

Ex. 2 was the same as Ex. 1, but the speed of the air swept pulverizerwas reduced as compared to the air swept pulverizer in Ex. 1. Raw wholecorn kernels were milled to produce hammermilled corn pieces. The hammermill was operated at about 90 Hz with a tip speed of about 124 metersper second (about 24,500 fpm) using a number 8 screen (3.175 mm) or (8/64″, or 0.125″) at a feed rate of about 925 kg/hr (about 2,040lbs/hr). The hammermilled corn pieces were pulverized in the air sweptpulverizer to produce the ground corn product. The air swept pulverizerwas operated at about 50 Hz with a tip speed of about 97.9 meters persecond (about 19,270 fpm) using three 43.18 cm (about 17-inch) diameterCCD beater plates and a CLP liner at a feed rate of about 599 kg/hr(about 1,320 lbs/hr).

Ex. 3 was whole corn that was only run through a disk mill fiberizer.Raw whole corn kernels were milled in the disk mill fiberizer to producethe ground corn product. The disk mill fiberizer used a 45.72 cm(18-inch) diameter TQ18-016 fine tooth plates set with a gap of about762 μm (about 0.030 inches) and was operated at about 60 Hz with a tipspeed of about 124 meters per second (about 24,500 fpm) at a feed rateof about 413 kg/hr (about 910 lbs/hr).

Ex. 4 was corn that was passed through a hammer mill and a disk millfiberizer. Raw whole corn kernels were milled to produce hammermilledcorn pieces. The hammer mill was operated at about 90 Hz with a tipspeed of about 124 meters per second (about 24,500 fpm) using a number 8screen (3.175 mm) or ( 8/64″, or 0.125″) at a feed rate of about 925kg/hr (about 2,040 lbs/hr). The hammermilled corn pieces were milled inthe disk mill fiberizer to produce the ground corn product. The diskmill fiberizer used 45.72 cm (about 18-inch) diameter TQ18-016 finetooth plates set with a gap of about 2.54 mm (about 0.100 inches) andwas operated at about 60 Hz with a tip speed of about 124 meters persecond (about 24,500 fpm) at a feed rate of about 1,890 kg/hr (about4,170 lbs/hr).

CEx. 1 was corn that was passed through a hammer mill. CEx. 2 was cornthat was run through a quad pair set up (a stack of 4 pairs of rolls)roller mill. The corn used in Exs. 1-4 were sourced locally inMuscatine, Iowa; the corn used in CEx. 1 was sourced from a Flint HillsResources Fairbank facility; and the corn used in CEx. 2 was sourcedfrom RMS in Tea, South Dakota.

Particle Size and Distribution

Table 1 shows the particle size by weight of the ground corn products asmeasured with sieves for Exs. 1-4 and CExs. 1-2. The sieves analysis wasconducted according to the AOAC Official Method 965.22 “Sorting CornGrits—Sieving Method,” available from the AOAC International. The weightpercent of the sample that was left on the specified sieve size had aparticle size larger than the respective sieve size. For example, inTable 1, the sample particles in Ex. 3 had the following weight percent(wt %) particles for the respective particle sizes: 0.10 wt % largerthan 850 μm, 3.60 wt % larger than 425 μm to 850 μm, 4.80 wt % largerthan 250 μm to 425 μm, 1.50 wt % larger than 180 μm to 250 μm, 14.90 wt% larger than 150 μm to 180 μm, 9.75 wt % larger than 105 μm to 150 μm,and 65.35 wt % 105 μm or less in the pan.

TABLE 1 Particle Size by Weight (measured with sieves) Sieve ParticleSize Size Weight Percent Left on Sieve (wt %) (μm) (μm) Ex. 1 Ex. 2 Ex.3 Ex. 4 CEx. 1 CEx. 2 850 >850 0.05 0.05 0.10 0.60 15.00 3.01 425 >425to 850 0.05 5.20 3.60 12.40 25.05 27.28 250 >250 to 425 2.10 14.05 4.8015.40 11.90 38.45 180 >180 to 250 1.20 24.55 1.50 9.10 6.30 10.40150 >150 to 180 21.90 15.55 14.90 4.80 3.90 9.13 105 >105 to 150 15.008.85 9.75 16.25 7.90 6.72 pan 105 and smaller 59.70 31.75 65.35 41.2529.95 5.02

Table 2 shows the particle size by volume of the ground corn productsand Table 3 shows the particle size distribution by volume of the groundcorn products that were analyzed on a LS™ 13-320 laser diffractionparticle size analyzer with a Tornado dry sample module attachment, bothcommercially available from Beckman Coulter Life Sciences. The laserdiffraction particle analysis was conducted according to the ISO13320:2009 “Particle Size Analysis Laser Diffraction Methods”.

The particle size by volume of the ground corn products shown in Table 2is smaller than the particle size listed. For example: 10 vol % of theparticles in the Ex. 3 sample had a particle size smaller than 17.68 μm.

TABLE 2 Particle Size by Volume (measured by laser diffraction) ParticleSize (μm) vol % Ex. 1 Ex. 2 Ex. 3 Ex. 4 CEx. 1 CEx. 2 10 18.34 24.9217.68 21.10 88.71 135.20 25 54.89 101.10 47.44 92.33 282.90 304.80 50168.70 287.30 167.10 285.00 686.50 531.60 75 404.20 630.30 486.70 587.401111.00 797.10 90 793.30 1097.00 967.70 876.20 1450.00 1125.00

Table 3 gives the complete distribution of particles within each of thelisted size ranges. For example: 28.3 vol % of the particles in the Ex.3 sample had a particle size of greater than 4 μm (e.g., about 4.01 μm)to about 60 μm.

TABLE 3 Volume % by Particle Size Particle Particle Size Distribution(vol %) Size (μm) Ex. 1 Ex. 2 Ex. 3 Ex. 4 CEx. 1 CEx. 2 0-4 0 0 0 0 00 >4-60 26.3 25.1 28.3 19.6 7.8 4.9 >60-400 48.5 49.5 42.5 40.2 23.929.8 >400-800  15.4 20.8 15.4 27.2 25.6 40.5  >800-2,000 9.9 4.6 13.913.0 42.7 24.8Oil and Grease Analysis

Each liquefaction sample was first centrifuged to separate the slurryinto separate phases. Each phase was subjected to oil and greaseanalysis. Oil and grease testing was performed on the SPE-DEX® 3000XLAutomated Extractor System and the SPEED-VAP™ Solvent EvaporationSystem, both commercially available from the Horizon Technology Company.The Horizon Technology automated extraction method, EPA Method 1664A,has been modified and validated to only remove liberated oil from thesample, leaving any oil that may be bound by the corn cellular matrix.The total average weight percent values are listed as the average of twoanalysis, summarized in Table 4.

TABLE 4 Percent recoveries of each slurry sample level after separationby centrifuge and their averages Sample Total average oil/grease (wt %)Ex. 1 0.97 Ex. 2 1.01 Ex. 3 1.03 Ex. 4 0.70 CEx. 1 0.26 CEx. 2 0.55

As shown in Table 4, the average amount of oil/grease recovered inExamples 1-4 was significantly greater than the amount of oil/greaserecovered in the Comparative Examples 1 and 2.

Microscopy Analysis

On each selected dry ground sample, microscopy was performed usingpolarized light and iodine staining on both a Wild Heerbrugg Observationmicroscope (10×) and an AmScope trinocular microscope (50×500×).Observation for starch and fiber were noted.

Analytical Methodology

Liquefaction

About 70 g of each ground corn sample was combined with about 200 mL ofwater having a temperature of about 80° C. to provide a slurry of about35 wt % of ground corn. About 1 mL of alpha amylase was added to theslurry. Enough 1.2 M HCl was added to each slurry to adjust the pH ofthe slurry to about 4. Each slurry sample was then placed in a shakerwater bath at about 85° C. for about 60 min. After removing slurrysample from the shaker bath, about 0.3 mL of 12 M HCl was added to lowerthe slurry pH and arrest the amylase activity. The time needed tocomplete each process of liquefaction for each sample slurry was keptconstant to limit sample to sample variability.

Oil and Grease Analysis

About 2 g of each ground corn sample and about 100 mL of diluteddistilled water were combined in a vial. Drops of HCl was added to thediluted sample in the vial until the pH of sample was adjusted to lessthan 2. Oil and grease extraction and testing was performed on theSPE-DEX® 3000XL Automated Extractor System and the SPEED-VAP™ SolventEvaporation System, both commercially available from the HorizonTechnology Company. The sample was processed by the extractor andevaporation systems using hexane as the extraction solvent. The resultsfor the oil and grease analysis are reported in Table 4.

Microscopy Analysis

For Comparative Examples 1-2 and Examples 1-4, microscopy was performedusing polarized light and iodine staining on both a Wild Heerbruggobservation microscope having a magnification of 10× (FIGS. 1, 3, 5, 7,9, and 11) and an AmScope trinocular microscope that had a magnificationof 50×-500× (FIGS. 2, 4, 6, 8, 10, and 12).

Iodine Staining Procedure

About 1 g of each ground corn sample was combined with 14 mL distilledwater in a 250 mL beaker. About 1 mL of pH 5 buffer was added to thesolution. About 84 mL of distilled water was combined with about 1.2 mLof a 0.5 N iodine solution and added to the sample slurry. One or twodrops of the sample was transferred to a slide and blended with about1-2 drops of an aqueous glycerin solution (about 50 wt % of glycerin andabout 50 wt % of water). A cover slip was placed on the sample and thesample was observed under the microscope at the referencedmagnifications. In the iodine stained sample under polarized light, adistinct Maltese cross formed in each of the starch particles. Particlesof fiber and other material appeared brown or showed no color on alightly blue hued background.

In the CEx. 1 sample of hammer milled corn, pericarp and flouryendosperm particles were viewed at 10× magnification (FIG. 1) and starchand fiber particles were viewed at 200× magnification (FIG. 3).

In the CEx. 2 sample of roller milled corn, pericarp and flouryendosperm particles were viewed at 10× magnification (FIG. 4) and starchand fiber particles were viewed at 200× magnification (FIG. 5).

In the Ex. 1 sample of disk pulverized corn, pericarp and flouryendosperm particles were viewed at 10× magnification (FIG. 6) and starchand fiber particles were viewed at 200× magnification (FIG. 7).

In the Ex. 2 sample of disk pulverized corn, pericarp and flouryendosperm particles were viewed at 10× magnification (FIG. 8) and starchand fiber particles were viewed at 100× magnification (FIG. 9).

In the Ex. 3 sample of disk fiberized corn, pericarp and flouryendosperm particles were viewed at 10× magnification (FIG. 10) andstarch and fiber particles were viewed at 200× magnification (FIG. 11).

In the Ex. 4 sample of disk fiberized corn, pericarp and flouryendosperm particles were viewed at 10× magnification (FIG. 12) andstarch and fiber particles were viewed at 200× magnification (FIG. 13).

Secondary Fermentation

Secondary fermentation was conducted on four fiber containing samples.The first sample (Comparative Example 3 (CEx. 3)) was a wet cakeproduced by separating ethanol from a fermentation mash to provide thewet cake. The ground corn that was subjected to the first or primaryfermentation that produced the fermentation mash was ground with ahammermill (Roskamp Champion Champion Series 48×38). The particle sizedistribution of the ground corn is similar to the CEx. 1 distributiongiven above. The whole stillage was not subjected to a fiber/proteinseparation process.

The second sample (Example 5 (Ex. 5)) was a fiber product produced byseparating a whole stillage into a fiber rich product and a proteinproduct. The ground corn that was subjected to the first or primaryfermentation that produced the fermentation mash from which the wholestillage was separated was ground with a hammermill (Roskamp ChampionChampion Series 48×38). The particle size distribution of the groundcorn was similar to the CEx. 1 distribution given above.

The third sample (Example 6 (Ex. 6)) was a fiber product produced byseparating a whole stillage into a fiber rich product and a proteinproduct. The ground corn that was subjected to the first or primaryfermentation that produced the fermentation mash from which the wholestillage was separated was ground with the disk mill fiberizer, i.e.,Model TOQ-18 fiberizer, manufactured by Reynolds Engineering &Equipment, Inc. in Muscatine, Iowa.

The fourth sample (Example 7 (Ex. 7)) was a fiber product produced byseparating a whole stillage into a fiber rich product and a proteinproduct. The ground corn that was subjected to the first or primaryfermentation that produced the fermentation mash from which the wholestillage was separated was ground with the disk mill fiberizer, i.e.,Model TOQ-18 fiberizer, manufactured by Reynolds Engineering &Equipment, Inc. in Muscatine, Iowa. This ground corn had a similarparticle size distribution as Example 3 above.

Ex 6 and Ex 7 were separate fermentation batches of different lots ofcorn that were milled to the same specification. The only difference inthe separation process that was used between Ex. 6 and Ex. 7 is that asmaller screen size was used to separate the fibers from the protein inthe whole stillage. More particularly, a fiber screen size of about 45μm was used to separate the fiber product of Ex. 6, whereas a fiberscreen size of about 20 μm was used to separate the fiber product of Ex.7. The filter used was an FF6 Fiber Filter from Vincent Corporation,Tampa Fla.

The composition of CEx. 3 and Exs. 5-7 was determined and the resultsare shown in Table 5 below.

TABLE 5 Compositional Analysis Total Structural Total C6 C5 FermentableInorganics Protein Extractives Acetate Lignin PolysaccharidePolysaccharide Sugars (C5 + Example (%) (%) (%) (%) (%) (%) (%) C6) %CEx. 3 5.89 21.35 6.00 0.59 26.34 22.19 16.40 43.26 Ex. 5 1.49 19.7317.24 1.70 16.29 21.84 20.98 48.08 Ex. 6 0.63 13.26 0.26 2.05 18.1230.48 42.56 82.18 Ex. 7 0.64 22.86 1.48 3.19 19.32 28.82 26.11 61.65*Bagasse 2.83 0.75 4.38 2.40 23.71 44.07 25.36 77.73 *Bagasse was abaseline sample used to validate the compositional analysis

A more detailed compositional analysis of the inorganics, extractives,C6 polysaccharides, and C5 polysaccharides is shown in Table 6 below.

TABLE 6 Compositional Analysis Continued Non- Structural StructuralWater Ethanol Inorganics Inorganics Extractables Extractables GlucanXylan Galactan Arabinan Mannan Starch Example (%) (%) (%) (%) (%) (%)(%) (%) (%) (%) CEx. 3 3.26 2.63 3.37 2.63 14.51 9.74 4.11 6.66 notdetected 3.57 Ex. 5 0.17 1.32 3.66 13.58 14.26 12.53 3.39 8.45 notdetected 4.19 Ex. 6 0.12 0.51 0.10 0.16 20.71 25.35 6.93 17.21 notdetected 2.84 Ex. 7 0.35 0.29 0.39 1.09 18.07 16.14 6.46 9.97 notdetected 4.29 *Bagasse 1.87 0.96 2.41 1.97 41.68 23.76 2.39 1.60 notdetected not detected *Bagasse was a baseline sample used to validatethe compositional analysis

The tests used to determine the amounts in Tables 5 and 6 above were thestandard tests used in the industry that are based on the NationalRenewable Energy Laboratory (NREL) Methods, NREL Chemical Analysis andStandard Testing Procedures: Determination of Ash in Biomass Version2005; Determination of Extractives in Biomass Version 2005;Determination of Total Solids in Biomass Version 2008; Determination ofStructural Carbohydrates and Lignin in Biomass Version 2012; andDetermination of Starch in Solid Biomass Sample Version 2005.

The ethanol potential per 1,000 kg of each fiber containing sample wascalculated and the results are shown in Table 7 below. The ethanolpotential was determined according to the procedure discussed anddescribed above. For illustrative purposes, the determination of theethanol potential of Ex. 6, a fiber rich product (FRP) was calculated asfollows.

The amount of glucan, galactan, mannan and starch (20.71 wt % of glucan,6.93 wt % of galactan, 0 wt % of mannan, and 2.84 wt % of starch) wereadded together and equaled a total of 30.48 wt % of glucan, galactan,mannan and starch. The amount (wt %) of the combined amount of glucan,galactan, mannan and starch was multiplied by 1,000 kg (0.3048×1,000) todetermine the amount of any glucan, galactan, mannan, and starch inkilograms per 1,000 kg of the FRP, which was equal to 304.8 kg ofglucan, galactan, mannan and starch per 1,000 kg of the FHP. The mass(kg) of glucan, galactan, mannan and starch per 1,000 kg of the FRP wasconverted to mass (kg) of monosaccharides per 1,000 kg of the FRP bymultiplying the mass of the glucan, galactan, mannan, and starch (304.8kg) by 1.11 to account for the molecule of water that adds to thepolysaccharides when the sugar monomers are hydrolyzed from thepolysaccharides, which was equal to 338.3 kg of monosaccharides per1,000 kg of the FRP. The mass (kg) of the monosaccharides per 1,000 kgof the FRP was multiplied by 0.51 to convert the kilograms ofmonosaccharides per 1,000 kg of the FRP to kilograms ethanol per 1,000kg of the FRP while assuming 100% of the theoretical yield, which wasequal to 172.5 kg of ethanol per 1,000 kg of the FRP. The 172.5 kg ofethanol per 1,000 kg of the FRP was converted to liters (L) per 1,000 kgof the FRP by dividing the 172.5 kg of ethanol per 1,000 kg of the FRPby 0.789 kg/liter, which was equal to 218.7 liters of ethanol per 1,000kg of the FRP. The 218.7 liters of ethanol per 1,000 kg of the FRP wasdivided by 3.789 to convert the amount of ethanol per 1,000 kg of theFRP to gallons of ethanol per 1,000 kg of the FRP, which was equal to57.7 gallons of ethanol per 1,000 kg of the FRP.

The same calculations were done for the amounts of xylan and arabinan.The amount of xylan and arabinan (25.35 wt % of xylan and 17.21 wt % ofarabinan) were added together and equaled a total of 42.56 wt % of xylanand arabinan. The amount (wt %) of the combined amount of xylan andarabinan was multiplied by 1,000 kg (0.4256×1,000 kg) to determine theamount of any xylan and arabinan in kilograms per 1,000 kg of the FRP,which was equal to 425.6 kg of xylan and arabinan per 1,000 kg of theFRP. The mass (kg) of xylan and arabinan per 1,000 kg of the FRP wasthen converted to the mass (kg) of monosaccharides per 1,000 kg of theFRP by multiplying the mass of the xylan and arabinan (425.6 kg) by1.136 to account for the molecule of water that adds to thepolysaccharides when the sugar monomers are hydrolyzed from thepolysaccharides, which was equal to 483.5 kg of monosaccharides per1,000 kg of the FRP. The mass (kg) of the monosaccharides per 1,000 kgof the FRP was multiplied by 0.51 to convert the kilograms ofmonosaccharides per 1,000 kg of the FRP to kilograms of ethanol per1,000 kg of the FRP while assuming 100% of the theoretical yield, whichwas equal to 246.6 kg of ethanol per 1,000 kg of the FRP. The 246.6 kgof ethanol per 1,000 kg of the FRP was converted to liters (L) per 1,000kg of the FRP by dividing the 246.6 kg of ethanol per 1,000 kg of theFRP by 0.789 kg/liter, which was equal to 312.5 liters of ethanol per1,000 kg of the FRP. The 312.5 liters of ethanol per 1,000 kg of the FRPwas divided by 3.789 to convert the amount of ethanol per 1,000 kg ofthe FRP to gallons of ethanol per 1,000 kg of the FRP, which was equalto 82.5 gallons of ethanol per 1,000 kg of the FRP.

Accordingly, the ethanol potential of the fiber rich product of Ex. 6was equal to the combined amount of ethanol derived from the glucan,galactan, mannan, and starch (57.7 gallons of ethanol per 1,000 kg ofthe FRP) and the amount of ethanol derived from xylan and arabinan (82.5gallons of ethanol per 1,000 kg of the FRP), which was equal to 140.2gallons of ethanol per 1,000 kg of fiber rich product.

TABLE 7 Ethanol Potential CEx. 3 (gallons of ethanol Ex. 5 Ex. 6 Ex. 7per 1,000 kilograms (gallons of ethanol (gallons of ethanol (gallons ofethanol of the wet cake on a per 1,000 kilograms per 1,000 kilograms per1,000 kilograms dry basis) of the FRP) of the FRP) of the FRP) Ethanol73.8 82.0 140.2 105.1 Potential

As shown in Table 7, the fiber product recovered from the whole stillagethat was produced with corn ground in the disk mill fiberizer (Exs. 6and 7) had a significantly greater ethanol potential than CEx. 3. Moreparticularly, Ex. 6 had the potential to make about 1.90 times theamount of ethanol as CEx. 3 and Ex. 7 had the potential to make about1.42 times the amount of ethanol as CEx. 3.

Acid Pretreatment of Fiber Containing Samples

The fiber samples (CEx. 3 and Exs. 5-7) were subjected to an acidpretreatment process to produce pre-treated fiber containing samples.All supplies were purchased from ThermoFisher and Sigma Aldrich and usedas received. The moisture level of each substrate was determined by themoisture balance and following the manufacturer's suggested usage.

The fiber containing samples were all pretreated to convert thehemicellulose to oligomers, xylose, and arabinose and to make thecellulose and hemicellulosic oligomers more accessible and digestible tocellulase enzymes. The acid used in these experiments was about 93%sulfuric acid containing about 7% water. The pretreatments were allsetup with a set amount of sample, water, and acid which were mixedtogether and placed in an autoclavable vessel or jar with a lid. The lidwas sealed. The full jar was placed into an autoclave and heated toabout 120° C. for about 2 hours.

The water in the acid as well as the water in the fiber containingsamples were accounted for in the calculations to maintain the requiredsolids and acid loadings. The added water was tap water from the City ofWichita, Kans. The amount of fiber containing sample was 100 grams on adry weight basis (DWB). Table 8 provides the setup for these examples.

TABLE 8 Acid Pretreatment Mass of Moisture Moisture Fiber Total WaterAcid Sample Content in Fiber DWB Weight Water Acid in Acid Loading (g)(%) (g) (g) (g) (g) (g) (g) (g/Kg) CEx. 3 219 54.3 119 100 300 80.6 0.540.04 5 Ex. 5 258.4 61.3 158.4 100 300 41 0.54 0.04 5 Ex. 6 111.6 10.411.6 100 300 187.8 0.54 0.04 5 Ex. 7 104.2 4 4.2 100 300 195.3 0.54 0.045

The acid-treated fiber containing material was allowed to cool uponremoval from the autoclave and the moisture content was determined tocalculate a recovery of pretreated fiber substrate.

Enzyme Hydrolysis of the Acid Pretreated Fiber Containing Samples

Once the acid pretreatments were completed, the acid pretreated solidswere hydrolyzed, which as discussed and described above can beaccomplished with two enzyme systems. The first system was a cocktail ofenzymes that is termed by the industry as a cellulase, but containsexo-glucanases, endo-gluconases, beta-glucosidase, and potentially somexylanase activity. The second enzyme system was a hemicellulase and maycontain a number of different activities including exo-xylanase,endo-xylanase, arabinose, esterase, and proteases. These enzymecocktails are available commercially from Novozymes (Franklinton N.C.)and DuPont (Wilmington Del.).

The specific process variables for the enzyme hydrolysis of the acidpretreated fiber containing samples is shown in Table 9 below. Themoisture or solids content of each acid pretreated fiber containingsample was used to determine the amount of wet material to use in orderto obtain 15 g of the acid pretreated fiber containing sample on a dryweight basis. This amount was weighed into an appropriately sizedplastic container (about 250 mL container) to hold 100 g of enzymehydrolysis solids and liquid) with a screw on lid (to provide a watertight seal), followed by the addition of water, the pH of each samplewas adjusted to about 5 to about 5.2, the enzyme was added, and the lidwas closed. The 250 mL containers were placed in a heated mechanicalshaker set to about 50° C. and a shake rpm of about 150. The hydrolysiswas allowed to proceed for a time of about 72 hours with the pH adjustedback to about 5 to about 5.2 at each 24 hour period. At 72 hours, thecontainers were removed from the shaker and the contents of eachcontainer was centrifuged to separate the residual solids from theliquid sugar solution. The separated sugar solution was filtered througha 0.20 μm syringe filter into HPLC vials or into a 96 well plate foranalysis to determine the amount of sugar released by pretreatment andenzyme hydrolysis.

TABLE 9 Process Conditions for Enzyme Hydrolyzed Acid Pretreated FiberContaining Samples Pretreated fiber Target Enzyme Enzyme containingFermentor As-is Makeup Dose Enzyme Dose Enzyme sample Solids DryPretreated Water (g Amount (g Amount to (mass (mass Pretreated Solids(g) - to Add enzyme/ to Add enzyme/ Add fraction) frac) Solids (g) Total(mL) g TS (g) g TS (g) CEx. 3 0.317 0.15 15 54.3 50.18 0.13 1.29 0.050.75 Ex. 5 0.363 0.15 15 41.3 56.38 0.13 1.29 0.05 0.75 Ex. 6 0.343 0.1515 43.7 53.97 0.13 1.29 0.05 0.75 Ex. 7 0.347 0.15 15 43.2 54.47 0.131.29 0.05 0.75

The results showing the sugar concentrations of the enzyme hydrolyzedacid pretreated fiber containing sample are shown in Table 10 below.Three separate sugar analysis were conducted for each example and theaverage of those three tests is shown in Table 10. The sugar analysisresults were collected from a YSI biochemistry analyzer (2950D YSIIncorporated, 1700/1725 Brannum Lane, Yellow Springs, Ohio 45387-1107USA.

TABLE 10 Sugar Concentrations for Enzyme Hydrolyzed Acid PretreatedFiber Containing Samples Feed Stock Glucose (g/L) Std. Dev. Xylose (g/L)Std. Dev. CEx. 3 14.5 3.33 3.6 0.39 Ex. 5 10.0 2.16 5.1 0.21 Ex. 6 35.52.30 6.6 1.34 Ex. 7 26.8 1.28 4.7 1.99

The results showing the sugar yields for each enzyme hydrolyzed acidpretreated fiber containing sample is shown in Table 11 below.

TABLE 11 Sugar Yields for Enzyme Hydrolyzed Acid Pretreated FiberContaining Samples Glucose Glucose Xylose Xylose Yield (%) Std Dev Yield(%) Std Dev CEx. 3 48.3 11.06 21.67 2.33 Ex. 5 32.58 7.05 24 0.97 Ex. 690.5 5.86 15.21 3.1 Ex. 7 71.85 3.44 17.27 7.24Base Pretreatment of Fiber Containing Samples

The structure of the fibers can also be disrupted with a base instead ofan acid. Accordingly, the fiber samples (CEx. 3 and Exs. 5-7) were alsosubjected to a base pretreatment process to produce pre-treated fibercontaining samples. Pretreatment with a base induces very littlehydrolysis compared to when an acid is used. The base partiallysolubilizes or swells the cellulose and hemicellulose.

The base used in these experiments was an aqueous ammonium hydroxidesolution containing about 30% ammonium hydroxide and about 70% water.The water in the base solution as well as the water in the substratewere accounted for in the calculations to maintain the solids and baseloadings required. The added water was tap water (City of WichitaKans.). The material was allowed to cool upon removal from the autoclavefollowed a new moisture determination and a weighing to calculate arecovery of pretreated fiber substrate. The base loading is calculatedfor ammonia (NH₃).

The base pretreatment was setup with a set amount of the fibercontaining material, water, and base that were mixed together and placedin an autoclavable vessel and the vessel was sealed with a lid. Thevessels were placed into an autoclave and heated to 120° C. for about 2hours. Table 12 provides the setup for these examples.

TABLE 12 Base Pretreatment Mass of Moisture Moisture Fiber Total WaterBase Sample Content in Fiber DWB Weight Water Base in Base Loading (g)(%) (g) (g) (g) (g) (g) (g) (g/Kg) CEx. 3 184.2 45.7 84.2 100 300 110.96.9 4.9 20 Ex. 5 258.4 61.3 158.4 100 300 36.7 6.9 4.9 20 Ex. 6 111.610.4 11.6 100 300 183.5 6.9 4.9 20 Ex. 7 104.2 4.0 4.2 100 300 190.9 6.94.9 20Enzyme Hydrolysis of the Base Pretreated Fiber Containing Samples

Once the base pretreatments were completed, the base pretreated solidswere hydrolyzed, which, as discussed above, can be accomplished with twoenzyme systems. The first system was a cocktail of enzymes that istermed by the industry as a cellulase, but contains exo-glucanases,endo-gluconases, beta-glucosidase, and potentially some xylanaseactivity. The second enzyme system was as a hemicellulase and maycontain a number of different activities including exo-xylanase,endo-xylanase, arabinose, esterase, and proteases. These enzymecocktails were acquired from Novozymes (Franklinton N.C.) and DuPont(Wilmington Del.).

The moisture or solids content of each base pretreated fiber containingsample was used to determine the amount of wet material to use in orderto obtain 15 g of the base pretreated fiber containing sample on a dryweight basis. This amount was weighed into an appropriately sizedplastic container (about 250 mL container) to hold 100 g of enzymehydrolysis solids and liquid) with a screw on lid (to provide a watertight seal), followed by the addition of water, the pH of each samplewas adjusted to about 5 to about 5.2, the enzyme was added, and the lidwas closed. The 250 mL containers were placed in a heated mechanicalshaker set to about 50° C. and a shake rpm of about 150. The hydrolysiswas allowed to proceed for a time of about 72 hours with the pH adjustedback to about 5 to about 5.2 at each 24 hour period. At 72 hours, thecontainers were removed from the shaker and the contents of eachcontainer was centrifuged to separate the residual solids from theliquid sugar solution. The separated sugar solution was filtered througha 0.20 μm syringe filter into HPLC vials or into a 96 well plate foranalysis to determine the amount of sugar released by pretreatment andenzyme hydrolysis. The specific process variables for the enzymehydrolysis of the base pretreated fiber containing samples is shown inTable 13 below.

TABLE 13 Process Conditions for Enzyme Hydrolyzed Base Pretreated FiberContaining Samples PT Target Enzyme Enzyme Material Fermentor As-isMakeup Dose Enzyme Dose Enzyme Solids Solids Dry Pretreated Water (gAmount (g Amount to (mass (mass Pretreated Solids (g) - to Add enzyme/to Add enzyme/ Add frac) frac) Solids (g) Total (mL) g TS (g) g TS (g)CEx. 3 0.281 0.15 15 53.4 45.31 0.06 0.94 0.03 0.38 Ex. 5 0.322 0.15 1546.6 52.1 0.06 0.94 0.03 0.38 Ex. 6 0.336 0.15 15 44.6 54.04 0.06 0.940.03 0.38 Ex. 7 0.368 0.15 15 40.8 57.93 0.06 0.94 0.03 0.38

The results showing the sugar concentrations of the enzyme hydrolyzedbase pretreated fiber containing sample is shown in Table 14 below.Three separate sugar analysis was conducted on each example and theaverage of those three tests is shown in Table 14. The sugar analysisresults were collected from a YSI biochemistry analyzer (2950D YSIIncorporated, 1700/1725 Brannum Lane, Yellow Springs, Ohio 45387-1107USA.

TABLE 14 Sugar Concentrations for Base Pretreated Fiber ContainingSamples Glucose (g/L) Std. Dev. Xylose (g/L) Std. Dev. CEx. 3 8.7 2.84.9 0.7 Ex. 5 11.3 3.3 6.8 1 Ex. 6 22.1 1 10.1 1 Ex. 7 14.1 3.6 8.9 0.6

The results showing the sugar yields for each enzyme hydrolyzed basepretreated fiber containing sample is shown in Table 15 below.

TABLE 15 Sugar Yields for Enzyme Hydrolyzed Base Pretreated FiberContaining Samples Glucose Glucose Xylose Xylose Yield (%) Std Dev Yield(%) Std Dev CEx. 3 28.81 9.39 29.25 4.05 Ex. 5 36.90 10.61 31.56 2.83Ex. 6 56.37 2.48 23.49 2.35 Ex. 7 37.89 9.71 32.29 2.36

Embodiments of the present disclosure further relate to any one or moreof the following paragraphs:

1. A process for making ethanol, comprising: processing a ground cornproduct to produce a fermentation mash comprising ethanol; separating atleast a portion of the ethanol from the fermentation mash to produce awhole stillage; and separating the whole stillage to produce a fiberrich product and a filtrate, wherein the fiber rich product has anethanol potential of at least 90 gallons of ethanol per 1,000 kilogramsof the fiber rich product.

2. A process for making ethanol, comprising: processing a ground cornproduct to produce a fermentation mash comprising ethanol; separating atleast a portion of the ethanol from the fermentation mash to produce awhole stillage; separating the whole stillage to produce a fiber richproduct and a filtrate; hydrolyzing the fiber rich product to produce asaccharification mash; and processing the saccharification mash toproduce additional ethanol and a stillage protein product.

3. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash comprising ethanol; separating at least a portion of the ethanolfrom the fermentation mash to produce a whole stillage; separating thewhole stillage with a fiber filter to produce a fiber rich product and afiltrate; hydrolyzing the fiber rich product to produce asaccharification mash; processing the saccharification mash to produceadditional ethanol and a stillage protein product.

4. A process for recovering products from a corn fermentation mash,comprising: separating ethanol from a fermentation mash to produce awhole stillage, wherein the fermentation mash is derived from a groundcorn product milled from a plurality of corn pieces, wherein theplurality of corn pieces comprises whole corn kernels, fragmented cornkernels, size-reduced corn kernels, milled corn kernels, or any mixturethereof, wherein greater than 80 wt % of the ground corn product has aparticle size of 425 μm or less, as measured according to AOAC965.22-1966; separating the whole stillage to produce a fiber richproduct and a filtrate; hydrolyzing the fiber rich product to produce asaccharification mash; and processing the saccharification mash toproduce additional ethanol and a stillage protein product.

5. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash comprising ethanol; separating at least a portion of the ethanolfrom the fermentation mash to produce a whole stillage; and separatingthe whole stillage with a separator to produce a fiber rich product anda filtrate, wherein the separator comprises a rotary drum screen, arotary vacuum drum filter, a brush strainer, a vibratory separator, alinear motion screen, a vacu-deck screen, or a combination thereof;hydrolyzing the fiber rich product to produce a saccharification mash;and processing the saccharification mash to produce additional ethanoland a stillage protein product.

6. A process for making ethanol, comprising: processing a ground cornproduct to produce a fermentation mash comprising ethanol; separating atleast a portion of the ethanol from the fermentation mash to produce awhole stillage; separating the whole stillage to produce a fiber richproduct and a filtrate; processing the fiber rich product to produceadditional ethanol and a stillage protein product comprising about 40 wt% to about 80 wt % of protein, about 3 wt % to about 20 wt % of fat,about 1 wt % to about 4 wt % of ash, about 2 wt % to about 30 wt % ofneutral detergent fibers, about 1 wt % to about 15 wt % of aciddetergent fibers, and about 15 wt % to about 35 wt % of yeast, based ona dry weight of the stillage protein product.

7. A process for making ethanol, comprising: processing a ground cornproduct to produce a fermentation mash comprising ethanol; separating atleast a portion of the ethanol from the fermentation mash to produce awhole stillage; separating the whole stillage to produce a fiber richproduct and a filtrate; processing the fiber rich product to produceadditional ethanol and a stillage protein product comprising about 15 wt% to about 35 wt % of yeast, based on a dry weight of the stillageprotein product.

8. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash comprising ethanol, wherein the ground corn product has a d₅₀ byvolume percent of 100 μm to 400 μm, as measured according to ISO13320:2009; separating at least a portion of the ethanol from thefermentation mash to produce a whole stillage; separating the wholestillage with a single pressure screen to produce a fiber rich productand a filtrate; and processing the fiber rich product to produceadditional ethanol and a stillage protein product.

9. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash, wherein the ground corn product has a d₅₀ by volume percent of 100μm to 400 μm, as measured according to ISO 13320:2009; separatingethanol from the fermentation mash to produce a whole stillage;separating the whole stillage with a fiber filter to produce a fiberrich product and a filtrate; and processing the fiber rich product toproduce additional ethanol and a stillage protein product.

10. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash, wherein greater than 25 wt % of the ground corn product has aparticle size of greater than 105 μm, and wherein greater than 80 wt %of the ground corn product has a particle size of 425 μm or less, asmeasured according to AOAC 965.22-1966; separating ethanol from thefermentation mash to produce a whole stillage; separating the wholestillage to produce a fiber rich product and a filtrate; hydrolyzing thefiber rich product to produce a saccharification mash; and processingthe saccharification mash to produce additional ethanol and a stillageprotein product.

11. A process for making ethanol, comprising: processing a ground cornproduct to produce a fermentation mash comprising ethanol; separatingethanol from the fermentation mash to produce a whole stillage;separating the whole stillage to produce a fiber rich product and afiltrate; and processing the fiber rich product to produce additionalethanol and a stillage protein product.

12. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash comprising ethanol; separating at least a portion of the ethanolfrom the fermentation mash to produce a whole stillage; separating thewhole stillage with a fiber filter to produce a fiber rich product and afiltrate; and processing the fiber rich product to produce additionalethanol and a stillage protein product.

13. A process for recovering products from a corn fermentation mash,comprising: separating ethanol from a fermentation mash to produce awhole stillage, wherein the fermentation mash is derived from a groundcorn product milled from a plurality of corn pieces, wherein theplurality of corn pieces comprises whole corn kernels, fragmented cornkernels, size-reduced corn kernels, milled corn kernels, or any mixturethereof, wherein greater than 80 wt % of the ground corn product has aparticle size of 425 μm or less, as measured according to AOAC965.22-1966; separating the whole stillage to produce a fiber richproduct and a filtrate; and processing the fiber rich product to produceadditional ethanol and a stillage protein product.

14. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash comprising ethanol; separating at least a portion of the ethanolfrom the fermentation mash to produce a whole stillage; and separatingthe whole stillage with a separator to produce a fiber rich product anda filtrate, wherein the separator comprises a rotary drum screen, arotary vacuum drum filter, a brush strainer, a vibratory separator, alinear motion screen, a vacu-deck screen, or a combination thereof; andprocessing the fiber rich product to produce additional ethanol and astillage protein product.

15. A process for recovering products from a corn fermentation mash,comprising: processing a ground corn product to produce a fermentationmash, wherein greater than 25 wt % of the ground corn product has aparticle size of greater than 105 μm, and wherein greater than 80 wt %of the ground corn product has a particle size of 425 μm or less, asmeasured according to AOAC 965.22-1966; separating ethanol from thefermentation mash to produce a whole stillage; separating the wholestillage to produce a fiber rich product and a filtrate; and processingthe fiber rich product to produce additional ethanol and a stillageprotein product.

16. The process according to any one of paragraphs 2 to 15, wherein thefiber rich product has an ethanol potential of at least 90 gallons ofethanol per 1,000 kilograms of the fiber rich product.

17. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 95 gallons ofethanol per 1,000 kilograms of the fiber rich product.

18. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 100 gallons ofethanol per 1,000 kilograms of the fiber rich product.

19. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 105 gallons ofethanol per 1,000 kilograms of the fiber rich product.

20. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 110 gallons ofethanol per 1,000 kilograms of the fiber rich product.

21. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 115 gallons ofethanol per 1,000 kilograms of the fiber rich product.

22. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 120 gallons ofethanol per 1,000 kilograms of the fiber rich product.

23. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 125 gallons ofethanol per 1,000 kilograms of the fiber rich product.

24. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 130 gallons ofethanol per 1,000 kilograms of the fiber rich product.

25. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 135 gallons ofethanol per 1,000 kilograms of the fiber rich product.

26. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of at least 140 gallons ofethanol per 1,000 kilograms of the fiber rich product.

27. The process according to any one of paragraphs 1 to 26, wherein thefiber rich product has an ethanol potential of up to about 145 gallonsof ethanol per 1,000 kilograms of the fiber rich product.

28. The process according to any one of paragraphs 1 to 26, wherein thefiber rich product has an ethanol potential of up to about 150 gallonsof ethanol per 1,000 kilograms of the fiber rich product.

29. The process according to any one of paragraphs 1 to 26, wherein thefiber rich product has an ethanol potential of up to about 155 gallonsof ethanol per 1,000 kilograms of the fiber rich product.

30. The process according to any one of paragraphs 1 to 26, wherein thefiber rich product has an ethanol potential of up to about 160 gallonsof ethanol per 1,000 kilograms of the fiber rich product.

31. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of about 100 gallons ofethanol per 1,000 kilograms of the fiber rich product to about 150gallons of ethanol per 1,000 kilograms of the fiber rich product.

32. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of about 135 gallons ofethanol per 1,000 kilograms of the fiber rich product to about 150gallons of ethanol per 1,000 kilograms of the fiber rich product.

33. The process according to any one of paragraphs 1 to 15, wherein thefiber rich product has an ethanol potential of about 95 gallons ofethanol per 1,000 kilograms of the fiber rich product to about 110gallons of ethanol per 1,000 kilograms of the fiber rich product.

34. The process according to any one of paragraphs 1 to 33, whereingreater than 80 wt % of the ground corn product has a particle size of425 μm or less, as measured according to AOAC 965.22-1966.

35. The process according to any one of paragraphs 1 to 34, wherein theground corn product has a d₅₀ by volume percent of 100 μm to 400 μm, asmeasured according to ISO 13320:2009.

36. The process according to any one of paragraphs 1 to 35, whereingreater than 85 wt % of the ground corn product has a particle size of425 μm or less, as measured according to AOAC 965.22-1966.

37. The process according to any one of paragraphs 1 to 36, wherein theground corn product has a crystallinity of greater than 75%, as comparedto a crystallinity of the corn pieces.

38. The process according to any one of paragraphs 1 to 37, whereingreater than 94 wt % of the ground corn product has a particle size of425 μm or less, as measured according to AOAC 965.22-1966.

39. The process according to any one of paragraphs 1 to 38, wherein theground corn product has a d₅₀ by volume percent of 120 μm to 350 μm, asmeasured according to ISO 13320:2009.

40. The process according to any one of paragraphs 1-4, 6, 7, 9, 10-13,and 15-39, wherein the whole stillage is separated with a fiber filterto produce the fiber rich product and the filtrate, and wherein thefiber filter comprises a filter sleeve having openings of about 10 lamto about 400 μm.

41. The process according to any one of paragraphs 1 to 40, furthercomprising: separating the filtrate to produce a protein rich portion,an oil product, and a clarified stillage.

42. The process according to paragraph 41, further comprising removingwater from the protein rich portion to produce a protein rich product.

43. The process according to paragraph 41 or 42, further comprisingremoving water from the clarified stillage to produce an evaporatedclarified stillage.

44. The process according to any one of paragraphs 1 to 43, wherein thestillage protein product comprises about 15 wt % to about 35 wt % ofyeast, based on a dry weight of the stillage protein product.

45. The process according to any one of paragraphs 1 to 43, wherein thestillage protein product comprises about 20 wt % to about 30 wt % ofyeast, based on a dry weight of the stillage protein product.

46. The process according to any one of paragraphs 1 to 43, wherein thestillage protein product comprises about 20 wt % to about 27 wt % ofyeast, based on a dry weight of the stillage protein product.

47. The process according to any one of paragraphs 1 to 43, wherein thestillage protein product comprises at least 20 wt % to about 30 wt % ofyeast, based on a dry weight of the stillage protein product.

48. The process according to any one of paragraphs 1 to 43, wherein thestillage protein product comprises about 40 wt % to about 80 wt % ofprotein, about 3 wt % to about 20 wt % of fat, about 1 wt % to about 4wt % of ash, about 2 wt % to about 30 wt % of neutral detergent fibers,about 1 wt % to about 15 wt % of acid detergent fibers, and about 15 wt% to about 35 wt % of yeast, based on a dry weight of the stillageprotein product.

49. The process according to any one of paragraphs 1 to 43, wherein thestillage protein product comprises about 47 wt % to about 57 wt % ofprotein, about 3 wt % to about 5 wt % of fat, about 1 wt % to about 3 wt% of ash, about 4 wt % to about 10 wt % of neutral detergent fibers,about 5 wt % to about 10 wt % of acid detergent fibers, and about 20 wt% to about 30 wt % of yeast, based on a dry weight of the stillageprotein product.

50. The process according to any one of paragraphs 2-5, 10, and 16-49,wherein the fiber rich product is contacted with an acid prior tohydrolyzing the fiber rich product to produce the saccharification mash.

51. The process according to any one of paragraphs 2-5, 10, and 16-49,wherein the fiber rich product is contacted with a base prior tohydrolyzing the fiber rich product to produce the saccharification mash.

52. The process according to any one of paragraphs 2-5, 10, and 16-49,wherein the fiber rich product is contacted with an acid and a baseprior to hydrolyzing the fiber rich product to produce thesaccharification mash.

53. The process according to paragraph 50 and 52, wherein the acidcomprises sulfuric acid, nitric acid, hydrochloric acid, phosphoricacid, strong acid resins, acetic acid, citric acid, trichloroaceticacid, or any mixture thereof.

54. The process according to any one of paragraphs 51-53, wherein thebase comprises ammonium hydroxide, potassium hydroxide, sodiumhydroxide, calcium hydroxide, magnesium hydroxide, strong base resins,sodium carbonate, potassium carbonate, lime, or any mixture thereof.

55. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises about at least 20 wt % of C5polysaccharides and at least 20 wt % of C6 polysaccharides, based on adried weight of the fiber rich product.

56. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises at least 23 wt % of C5 polysaccharides andat least 24 wt % of C6 polysaccharides, based on a dried weight of thefiber rich product.

57. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises about 23 wt % to about 34 wt % of C5polysaccharides and about 25 wt % to about 35 wt % of C6polysaccharides, based on a dried weight of the fiber rich product.

58. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises about 24 wt % to about 28 wt % of C5polysaccharides and about 27 wt % to about 30 wt % of C6polysaccharides, based on a dried weight of the fiber rich product.

59. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises about 38 wt % to about 45 wt % of C5polysaccharides and about 28 wt % to about 33 wt % of C6polysaccharides, based on a dried weight of the fiber rich product.

60. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises about 12 wt % to about 22 wt % of glucan,about 11 wt % to about 28 wt % of xylan, about 2.5 wt % to about 8 wt %of galactan, about 7 wt % to about 20 wt % of arabinan, and about 2 wt %to about 5 wt % of starch, based on the dried weight of the fiberproduct.

61. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises about 16 wt % to about 22 wt % of glucan,about 14 wt % to about 28 wt % of xylan, about 5 wt % to about 8 wt % ofgalactan, about 8 wt % to about 20 wt % of arabinan, and about 3.7 wt %to about 5 wt % of starch, based on the dried weight of the fiberproducts.

62. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises at least 16 wt % of glucan, at least 15 wt% of xylan, at least 5 wt % of galactan, at least 9 wt % of arabinan,and at least 2 wt % of starch, based on the dried weight of the fiberproducts.

63. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises at least 18 wt % of glucan, at least 16 wt% of xylan, at least 6 wt % of galactan, at least 9 wt % of arabinan,and at least 2 wt % of starch, based on the dried weight of the fiberproducts.

64. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises at least 20 wt % of glucan, at least 20 wt% of xylan, at least 6 wt % of galactan, at least 15 wt % of arabinan,and at least 2 wt % of starch, based on the dried weight of the fiberproducts.

65. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises less than 1 wt % of inorganic compounds,less than 1 wt % of extractives, about 1.5 wt % to about 3 wt % ofacetate, about 28 wt % to about 33 wt % of C6 polysaccharides, and about38 wt % to about 45 wt % of C5 polysaccharides, based on a dried weightof the fiber rich products.

66. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises less than 1 wt % of inorganic compounds,about 10 wt % to about 16 wt % of structural protein, less than 1 wt %of extractives, about 1.5 wt % to about 3 wt % of acetate, about 28 wt %to about 33 wt % of C6 polysaccharides, and about 38 wt % to about 45 wt% of C5 polysaccharides, based on a dried weight of the fiber richproducts.

67. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises less than 1 wt % of inorganic compounds,about 10 wt % to about 16 wt % of structural protein, less than 1 wt %of extractives, about 1.5 wt % to about 3 wt % of acetate, about 17 wt %to about 22 wt % of lignin, about 28 wt % to about 33 wt % of C6polysaccharides, and about 38 wt % to about 45 wt % of C5polysaccharides, based on a dried weight of the fiber rich products.

68. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises less than 1 wt % of the inorganiccompounds, less than 2 wt % of the extractives, about 1.8 wt % to about4 wt % of acetate, about 27 wt % to about 30 wt % of C6 polysaccharides,and about 24 wt % to about 28 wt % of C5 polysaccharides, based on adried weight of the fiber rich products.

69. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises less than 1 wt % of the inorganiccompounds, about 20 wt % to about 26 wt % of structural protein, lessthan 2 wt % of the extractives, about 2 wt % to about 4 wt % of acetate,about 27 wt % to about 30 wt % of C6 polysaccharides, and about 24 wt %to about 28 wt % of C5 polysaccharides, based on a dried weight of thefiber rich products.

70. The process according to any one of paragraphs 1 to 54, wherein thefiber rich product comprises less than 1 wt % of the inorganiccompounds, less than 2 wt % of the extractives, about 1.8 wt % to about4 wt % of acetate, about 20 wt % to about 25 wt % of structural protein,about 17 wt % to about 22 wt % of lignin, about 27 wt % to about 30 wt %of C6 polysaccharides, and about 24 wt % to about 28 wt % of C5polysaccharides, based on a dried weight of the fiber rich products.

71. The process according to any one of paragraphs 1, 2, 4, 6, 7, 10,11, 13, and 15-70, wherein the whole stillage is separated with a fiberfilter to produce the fiber rich product and the filtrate.

72. The process according to any one of paragraphs 3, 9, 12, and 16 to71, wherein the fiber filter comprises a filter sleeve and a rotordisposed within the filter sleeve.

73. The process according to any one of paragraphs 3, 9, 12, and 16 to71, wherein the fiber filter comprises a filter sleeve and a rotordisposed within the filter sleeve, and wherein the filter sleevecomprises a woven polymer fabric.

74. The process according to paragraph 72 or 73, wherein the filtersleeve has openings of 500 μm or less.

75. The process according to paragraph 72 or 73, wherein the filtersleeve has openings of about 10 μm to less than 400 μm.

76. The process according to paragraph 72 or 73, wherein the filtersleeve has openings of about 12 μm to about 200 μm.

77. The process according to any one of paragraphs 1 to 76, wherein atleast 10 wt % of the ground corn product has a particle size of lessthan 100 μm, as measured according to AOAC 965.22-1966.

78. The process according to any one of paragraphs 1 to 76, wherein atleast 15 wt % of the ground corn product has a particle size of lessthan 100 μm, as measured according to AOAC 965.22-1966.

79. The process according to any one of paragraphs 1 to 76, wherein atleast 20 wt % of the ground corn product has a particle size of lessthan 100 μm, as measured according to AOAC 965.22-1966.

80. The process according to any one of paragraphs 1 to 76, wherein atleast 25 wt % of the ground corn product has a particle size of lessthan 100 μm, as measured according to AOAC 965.22-1966.

81. The process according to any one of paragraphs 1 to 76, wherein atleast 30 wt % of the ground corn product has a particle size of lessthan 100 μm, as measured according to AOAC 965.22-1966.

82. The process according to any one of paragraphs 1 to 76, wherein atleast 35 wt % of the ground corn product has a particle size of lessthan 100 μm, as measured according to AOAC 965.22-1966.

83. The process according to any one of paragraphs 1 to 76, wherein atleast 40 wt % of the ground corn product has a particle size of lessthan 100 μm, as measured according to AOAC 965.22-1966.

84. The process according to any one of paragraphs 1 to 83, whereingreater than 25 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966.

85. The process according to any one of paragraphs 1 to 83, whereingreater than 30 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966.

86. The process according to any one of paragraphs 1 to 83, whereingreater than 35 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966.

87. The process according to any one of paragraphs 1 to 83, whereingreater than 40 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966.

88. The process according to any one of paragraphs 1 to 83, whereingreater than 45 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966.

89. The process according to any one of paragraphs 1 to 83, whereingreater than 50 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966.

90. A fiber rich product having an ethanol potential of at least 90gallons of ethanol per 1,000 kilograms of the fiber rich product,wherein the fiber rich product is separated from a fermentation mashproduced by fermenting a ground corn product.

91. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 95 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

92. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 100 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

93. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 105 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

94. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 110 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

95. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 115 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

96. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 120 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

97. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 125 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

98. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 130 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

99. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 135 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

100. The fiber rich product according to paragraph 90, wherein the fiberrich product has an ethanol potential of at least 140 gallons of ethanolper 1,000 kilograms of the fiber rich product, wherein the fiber richproduct is separated from a fermentation mash produced by fermenting aground corn product.

101. The fiber rich product according to any one of paragraphs 90 to100, wherein the fiber rich product has an ethanol potential of up toabout 145 gallons of ethanol per 1,000 kilograms of the fiber richproduct, wherein the fiber rich product is separated from a fermentationmash produced by fermenting a ground corn product.

102. The fiber rich product according to any one of paragraphs 90 to100, wherein the fiber rich product has an ethanol potential of up toabout 150 gallons of ethanol per 1,000 kilograms of the fiber richproduct, wherein the fiber rich product is separated from a fermentationmash produced by fermenting a ground corn product.

103. The fiber rich product according to any one of paragraphs 90 to100, wherein the fiber rich product has an ethanol potential of up toabout 155 gallons of ethanol per 1,000 kilograms of the fiber richproduct, wherein the fiber rich product is separated from a fermentationmash produced by fermenting a ground corn product.

104. The fiber rich product according to any one of paragraphs 90 to100, wherein the fiber rich product has an ethanol potential of up toabout 160 gallons of ethanol per 1,000 kilograms of the fiber richproduct, wherein the fiber rich product is separated from a fermentationmash produced by fermenting a ground corn product.

105. The fiber rich product according to any one of paragraphs 90 to104, wherein greater than 80 wt % of the ground corn product has aparticle size of 425 μm or less, as measured according to AOAC965.22-1966.

106. The fiber rich product according to any one of paragraphs 90 to105, wherein greater than 25 wt % of the ground corn product has aparticle size of greater than 105 μm, as measured according to AOAC965.22-1966.

107. The fiber rich product according to any one of paragraphs 90 to106, wherein the ground corn product has a d₅₀ by volume percent of 100μm to 400 μm, as measured according to ISO 13320:2009.

108. The fiber rich product according to any one of paragraphs 90 to106, wherein greater than 85 wt % of the ground corn product has aparticle size of 425 μm or less, as measured according to AOAC965.22-1966, and wherein the ground corn product has a crystallinity ofgreater than 75%, as compared to a crystallinity of the corn pieces.

109. The fiber rich product according to any one of paragraphs 90 to108, wherein the ground corn product is produced by grinding corn in anair swept pulverizer.

110. The fiber rich product according to any one of paragraphs 90 to108, wherein the ground corn product is produced by grinding corn in adisk mill fiberizer.

111. A fiber rich product comprising at least 20 wt % of C5polysaccharides and at least 20 wt % of C6 polysaccharides, based on adried weight of the fiber rich product, wherein the fiber rich productis separated from a fermentation mash produced by fermenting a groundcorn product.

112. The fiber rich product according to paragraph 111, wherein thefiber rich product comprises at least 23% of C5 polysaccharides and atleast 24 wt % of C6 polysaccharides, based on a dried weight of thefiber rich product.

113. The fiber rich product according to paragraph 111 or 112, whereinthe fiber rich product comprises up to about 45 wt % of C5polysaccharides and up to about 35 wt % of C6 polysaccharides, based ona dried weight of the fiber rich product.

114. The fiber rich product according to paragraph 111, wherein thefiber rich product comprises about 24 wt % to about 28 wt % of C5polysaccharides and about 27 wt % to about 30 wt % of C6polysaccharides, based on a dried weight of the fiber rich product.

115. The fiber rich product according to paragraph 111, wherein thefiber rich product comprises about 38 wt % to about 45 wt % of C5polysaccharides and about 28 wt % to about 33 wt % of C6polysaccharides, based on a dried weight of the fiber rich product.

116. A fiber rich product, comprising about 12 wt % to about 22 wt % ofglucan, about 11 wt % to about 28 wt % of xylan, about 2.5 wt % to about8 wt % of galactan, about 7 wt % to about 20 wt % of arabinan, and about2 wt % to about 5 wt % of starch, based on a dried weight of the fiberrich product, wherein the fiber rich product is separated from afermentation mash produced by fermenting a ground corn product.

117. The fiber rich product according to paragraph 116, wherein thefiber rich product comprises about 16 wt % to about 22 wt % of glucan,about 14 wt % to about 28 wt % of xylan, about 5 wt % to about 8 wt % ofgalactan, about 8 wt % to about 20 wt % of arabinan, and about 3.7 wt %to about 5 wt % of starch, based on the dried weight of the fiberproducts.

118. The fiber rich product according to paragraph 116, wherein thefiber rich product comprises at least 16 wt % of glucan, at least 15 wt% of xylan, at least 5 wt % of galactan, at least 9 wt % of arabinan,and at least 2 wt % of starch, based on the dried weight of the fiberproducts.

119. The fiber rich product according to paragraph 116, wherein thefiber rich product comprises at least 18 wt % of glucan, at least 16 wt% of xylan, at least 6 wt % of galactan, at least 9 wt % of arabinan,and at least 2 wt % of starch, based on the dried weight of the fiberproducts.

120. The fiber rich product according to paragraph 116, wherein thefiber rich product comprises at least 20 wt % of glucan, at least 20 wt% of xylan, at least 6 wt % of galactan, at least 15 wt % of arabinan,and at least 2 wt % of starch, based on the dried weight of the fiberproducts.

121. The fiber rich product according to any one of paragraphs 111 to120, wherein the fiber rich product comprises less than 1 wt % ofinorganic compounds, less than 1 wt % of extractives, and about 1.5 wt %to about 3 wt % of acetate, based on a dried weight of the fiber richproducts.

122. The fiber rich product according to any one of paragraphs 111 to120, wherein the fiber rich product comprises less than 1 wt % ofinorganic compounds, about 10 wt % to about 16 wt % of structuralprotein, less than 1 wt % of extractives, and about 1.5 wt % to about 3wt % of acetate, based on a dried weight of the fiber rich products.

123. The fiber rich product according to any one of paragraphs 111 to120, wherein the fiber rich product comprises less than 1 wt % ofinorganic compounds, about 10 wt % to about 16 wt % of structuralprotein, less than 1 wt % of extractives, about 1.5 wt % to about 3 wt %of acetate, and about 17 wt % to about 22 wt % of lignin, based on adried weight of the fiber rich products.

124. The fiber rich product according to any one of paragraphs 111 to120, wherein the fiber rich product comprises less than 1 wt % of theinorganic compounds, less than 2 wt % of the extractives, and about 1.8wt % to about 4 wt % of acetate, based on a dried weight of the fiberrich products.

125. The fiber rich product according to any one of paragraphs 111 to120, wherein the fiber rich product comprises less than 1 wt % of theinorganic compounds, about 20 wt % to about 26 wt % of structuralprotein, less than 2 wt % of the extractives, and about 2 wt % to about4 wt % of acetate, based on a dried weight of the fiber rich products.

126. The fiber rich product according to any one of paragraphs 111 to120, wherein the fiber rich product comprises less than 1 wt % of theinorganic compounds, less than 2 wt % of the extractives, about 1.8 wt %to about 4 wt % of acetate, about 20 wt % to about 25 wt % of structuralprotein, and about 17 wt % to about 22 wt % of lignin, based on a driedweight of the fiber rich products.

127. A stillage protein product comprising about 40 wt % to about 80 wt% of protein, about 3 wt % to about 20 wt % of fat, about 1 wt % toabout 4 wt % of ash, about 2 wt % to about 30 wt % of neutral detergentfibers, and about 1 wt % to about 15 wt % of acid detergent fibers,based on a dry weight of the stillage protein product.

128. A stillage protein product comprising about 40 wt % to about 80 wt% of protein, about 3 wt % to about 20 wt % of fat, about 1 wt % toabout 4 wt % of ash, about 2 wt % to about 30 wt % of neutral detergentfibers, about 1 wt % to about 15 wt % of acid detergent fibers, andabout 15 wt % to about 30 wt % of yeast, based on a dry weight of thestillage protein product.

129. The stillage protein product according to paragraphs 127 and 128,wherein the stillage protein product comprises about 20 wt % to about 30wt % of yeast, based on a dry weight of the stillage protein product.

130. The stillage protein product according to any one of paragraphs 127to 129, wherein the stillage protein product comprises about 20 wt % toabout 27 wt % of yeast, based on a dry weight of the stillage proteinproduct.

131. The stillage protein product according to any one of paragraphs 127to 130, wherein the stillage protein product comprises at least 20 wt %to about 30 wt % of yeast, based on a dry weight of the stillage proteinproduct.

132. The stillage protein product according to any one of paragraphs 127to 131, wherein the stillage protein product comprises about 40 wt % toabout 80 wt % of protein, about 3 wt % to about 20 wt % of fat, about 1wt % to about 4 wt % of ash, about 2 wt % to about 30 wt % of neutraldetergent fibers, about 1 wt % to about 15 wt % of acid detergentfibers, and about 15 wt % to about 35 wt % of yeast, based on a dryweight of the stillage protein product.

133. The stillage protein product according to any one of paragraphs 127to 132, wherein the stillage protein product comprises about 47 wt % toabout 57 wt % of protein, about 3 wt % to about 5 wt % of fat, about 1wt % to about 3 wt % of ash, about 4 wt % to about 10 wt % of neutraldetergent fibers, about 5 wt % to about 10 wt % of acid detergentfibers, and about 20 wt % to about 30 wt % of yeast, based on a dryweight of the stillage protein product.

134. The stillage protein product according to any one of paragraphs 127to 133, wherein the stillage protein product is produced by processing afiber rich product separated from a whole stillage, wherein the wholestillage is separated from a fermentation mash produced by processing aground corn product.

135. The stillage protein product according to any one of paragraphs 127to 133, wherein the stillage protein product is separated from afermented saccharification mash, wherein the saccharification mash isproduced by hydrolyzing a fiber rich product, and wherein the fiber richproduct is separated from a whole stillage, and wherein the wholestillage is separated from a fermentation mash produced by processing aground corn product.

136. A process for recovering products from a fermentation mash,comprising: separating ethanol from a fermentation mash to produce awhole stillage, wherein the fermentation mash is derived from a groundcorn product milled from a plurality of corn pieces, wherein theplurality of corn pieces comprises whole corn kernels, fragmented cornkernels, size-reduced corn kernels, milled corn kernels, or any mixturethereof, wherein greater than 80 wt % of the ground corn product has aparticle size of 425 μm or less, as measured according to AOAC965.22-1966; separating the whole stillage to produce a fiber richproduct and a filtrate; hydrolyzing the fiber rich product to produce asaccharification mash; and processing the saccharification mash toproduce additional ethanol and a stillage protein product.

137. The process according to paragraph 136, wherein the fiber richproduct is contacted with an acid or a base prior to hydrolyzing thefiber rich product to produce the saccharification mash.

138. The process according to paragraph 136 and 137, wherein the fiberrich product has an ethanol potential of at least 90 gallons of ethanolper 1,000 kilograms of the fiber rich product.

139. The process according to any one of paragraphs 136 to 138, whereinthe fiber rich product has an ethanol potential of about 100 gallons ofethanol per 1,000 kilograms of the fiber rich product to about 150gallons of ethanol per 1,000 kilograms of the fiber rich product.

140. The process according to any one of paragraphs 136 to 139, whereinthe fiber rich product has an ethanol potential of about 130 gallons ofethanol per 1,000 kilograms of the fiber rich product to about 150gallons of ethanol per 1,000 kilograms of the fiber rich product.

141. The process according to any one of paragraphs 136 to 140, whereingreater than 25 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966.

142. The process according to any one of paragraphs 136 to 137, wherein:greater than 25 wt % of the ground corn product has a particle size ofgreater than 105 μm, as measured according to AOAC 965.22-1966, thefiber rich product has an ethanol potential of at least 90 gallons ofethanol per 1,000 kilograms of the fiber rich product, the fiber richproduct is contacted with an acid or a base to produce the pretreatedfiber rich product, and the stillage protein product comprises about 40wt % to about 80 wt % of protein, about 3 wt % to about 20 wt % of fat,about 1 wt % to about 4 wt % of ash, about 2 wt % to about 30 wt % ofneutral detergent fibers, about 1 wt % to about 15 wt % of aciddetergent fibers, and about 15 wt % to about 35 wt % of yeast, based ona dry weight of the stillage protein product.

143. The process, the fiber rich product, or the stillage proteinproduct according to any one of paragraphs 1 to 142, wherein the groundcorn product is produced by dry grinding.

144. The process, the fiber rich product, or the stillage proteinproduct according to any one of paragraphs 1 to 143, wherein the groundcorn product is milled from a plurality of corn pieces by one or morehigh shear mills.

145. The process, the fiber rich product, or the stillage proteinproduct according to any one of paragraphs 1 to 144, wherein the groundcorn product is milled from a plurality of corn pieces by one or moredisk mill fiberizers.

146. The process, the fiber rich product, or the stillage proteinproduct according to any one of paragraphs 1 to 145, wherein the groundcorn product is milled from a plurality of corn pieces by one or moreair swept pulverizers.

Certain embodiments and features have been described using a set ofnumerical upper limits and a set of numerical lower limits. It should beappreciated that ranges including the combination of any two values,e.g., the combination of any lower value with any upper value, thecombination of any two lower values, and/or the combination of any twoupper values are contemplated unless otherwise indicated. Certain lowerlimits, upper limits and ranges appear in one or more claims below. Allnumerical values are “about” or “approximately” the indicated value, andtake into account experimental error and variations that would beexpected by a person having ordinary skill in the art.

Various terms have been defined above. To the extent a term used in aclaim is not defined above, it should be given the broadest definitionpersons in the pertinent art have given that term as reflected in atleast one printed publication or issued patent. And if applicable, allpatents, test procedures, and other documents cited in this applicationare fully incorporated by reference to the extent such disclosure is notinconsistent with this application and for all jurisdictions in whichsuch incorporation is permitted.

While the foregoing is directed to certain illustrative embodiments,other and further embodiments of the invention can be devised withoutdeparting from the basic scope thereof, and the scope thereof isdetermined by the claims that follow.

What is claimed is:
 1. A process for recovering products from afermentation mash, comprising: processing a ground corn product toproduce a fermentation mash comprising ethanol; separating at least aportion of the ethanol from the fermentation mash to produce a wholestillage; separating the whole stillage to produce a fiber rich productand a filtrate; hydrolyzing the fiber rich product to produce asaccharification mash; and processing the saccharification mash toproduce additional ethanol and a stillage protein product; whereingreater than 25 wt % of the ground corn product has a particle size ofgreater than 105 μm, and greater than 80 wt % of the ground corn producthas a particle size of 425 μm or less, as measured according to AOAC965.22-1966.
 2. The process of claim 1, wherein the stillage proteinproduct comprises about 15 wt % to about 35 wt % of yeast, based on adry weight of the stillage protein product.
 3. The process of claim 1,wherein the stillage protein product comprises about 40 wt % to about 80wt % of protein, about 3 wt % to about 20 wt % of fat, about 1 wt % toabout 4 wt % of ash, about 2 wt % to about 30 wt % of neutral detergentfibers, about 1 wt % to about 15 wt % of acid detergent fibers, andabout 15 wt % to about 35 wt % of yeast, based on a dry weight of thestillage protein product.
 4. The process of claim 1, wherein thestillage protein product comprises about 47 wt % to about 57 wt % ofprotein, about 3 wt % to about 5 wt % of fat, about 1 wt % to about 3 wt% of ash, about 4 wt % to about 10 wt % of neutral detergent fibers,about 5 wt % to about 10 wt % of acid detergent fibers, and about 20 wt% to about 30 wt % of yeast, based on a dry weight of the stillageprotein product.
 5. The process of claim 1, wherein the fiber richproduct has an ethanol potential of at least 90 gallons of ethanol per1,000 kilograms of the fiber rich product.
 6. The process of claim 1,wherein the fiber rich product has an ethanol potential of about 100gallons of ethanol per 1,000 kilograms of the fiber rich product toabout 150 gallons of ethanol per 1,000 kilograms of the fiber richproduct.
 7. The process of claim 1, wherein the fiber rich product iscontacted with an acid or a base prior to hydrolyzing the fiber richproduct to produce the saccharification mash.
 8. The process of claim 1,wherein: the fiber rich product has an ethanol potential of about 100gallons of ethanol per 1,000 kilograms of the fiber rich product toabout 150 gallons of ethanol per 1,000 kilograms of the fiber richproduct, the fiber rich product is contacted with an acid or a baseprior to hydrolyzing the fiber rich product to produce thesaccharification mash, and the stillage protein product comprises about40 wt % to about 80 wt % of protein, about 3 wt % to about 20 wt % offat, about 1 wt % to about 4 wt % of ash, about 2 wt % to about 30 wt %of neutral detergent fibers, about 1 wt% to about 15 wt % of aciddetergent fibers, and about 15 wt % to about 35 wt % of yeast, based ona dry weight of the stillage protein product.
 9. A process forrecovering products from a fermentation mash, comprising: processing aground corn product to produce a fermentation mash comprising ethanol;separating at least a portion of the ethanol from the fermentation mashto produce a whole stillage; separating the whole stillage with a fiberfilter to produce a fiber rich product and a filtrate; hydrolyzing thefiber rich product to produce a saccharification mash; and processingthe saccharification mash to produce additional ethanol and a stillageprotein product; wherein greater than 25 wt % of the ground corn producthas a particle size of greater than 105 μm, and greater than 80 wt % ofthe ground corn product has a particle size of 425 μm or less, asmeasured according to AOAC 965.22-1966.
 10. The process of claim 9,wherein the fiber filter comprises a filter sleeve having openings ofabout 10 pm to less than 400 μm.
 11. The process of claim 9, wherein thefiber filter comprises a filter sleeve and a rotor disposed within thefilter sleeve, and wherein the filter sleeve comprises a woven polymerfabric.
 12. The process of claim 9, wherein the fiber rich product hasan ethanol potential of at least 90 gallons of ethanol per 1,000kilograms of the fiber rich product.
 13. The process of claim 9, whereinthe fiber rich product has an ethanol potential of about 100 gallons ofethanol per 1,000 kilograms of the fiber rich product to about 150gallons of ethanol per 1,000 kilograms of the fiber rich product. 14.The process of claim 9, wherein the stillage protein product comprisesabout 40 wt % to about 80 wt % of protein, about 3 wt % to about 20 wt %of fat, about 1 wt % to about 4 wt % of ash, about 2 wt % to about 30 wt% of neutral detergent fibers, about 1 wt % to about 15 wt % of aciddetergent fibers, and about 15 wt % to about 35 wt% of yeast, based on adry weight of the stillage protein product.
 15. The process of claim 9,wherein the stillage protein product comprises about 47 wt % to about 57wt % of protein, about 3 wt % to about 5 wt % of fat, about 1 wt % toabout 3 wt % of ash, about 4 wt % to about 10 wt % of neutral detergentfibers, about 5 wt % to about 10 wt % of acid detergent fibers, andabout 20 wt % to about 30 wt % of yeast, based on a dry weight of thestillage protein product.
 16. The process of claim 9, wherein: the fiberfilter comprises a filter sleeve having openings of about 10 μm to lessthan 400 μm, the fiber rich product has an ethanol potential of at least90 gallons of ethanol per 1,000 kilograms of the fiber rich product, andthe stillage protein product comprises about 40 wt % to about 80 wt % ofprotein, about 3 wt % to about 20 wt % of fat, about 1 wt % to about 4wt % of ash, about 2 wt % to about 30 wt % of neutral detergent fibers,about 1 wt % to about 15 wt % of acid detergent fibers, and about 15 wt% to about 35 wt % of yeast, based on a dry weight of the stillageprotein product.
 17. A process for recovering products from afermentation mash, comprising: processing a ground corn product toproduce a fermentation mash comprising ethanol; separating at least aportion of the ethanol from the fermentation mash to produce a wholestillage; and separating the whole stillage to produce a fiber richproduct and a filtrate, wherein the fiber rich product has an ethanolpotential of at least 90 gallons of ethanol per 1,000 kilograms of thefiber rich product; wherein greater than 25 wt % of the ground cornproduct has a particle size of greater than 105 μm, and greater than 80wt % of the ground corn product has a particle size of 425 μm or less,as measured according to AOAC 965.22-1966.
 18. The process of claim 17,wherein the fiber rich product has an ethanol potential of about 100gallons of ethanol per 1,000 kilograms of the fiber rich product toabout 150 gallons of ethanol per 1,000 kilograms of the fiber richproduct.
 19. The process of claim 17, wherein the fiber rich product hasan ethanol potential of about 135 gallons of ethanol per 1,000 kilogramsof the fiber rich product to about 150 gallons of ethanol per 1,000kilograms of the fiber rich product.
 20. The process of claim 17,wherein the whole stillage is separated with a fiber filter to producethe fiber rich product and the filtrate, and wherein the fiber filtercomprises a filter sleeve having openings of about 10 μm to about 400μm.
 21. The process of claim 17, further comprising: separating thefiltrate to produce a protein rich portion, an oil product, and aclarified stillage; removing water from the protein rich portion toproduce a protein rich product; and removing water from the clarifiedstillage to produce an evaporated clarified stillage.